FSP3: Produktion
Refine
Year of publication
Document Type
- conference proceeding (article) (72)
- Article (66)
- conference proceeding (presentation) (20)
- Part of a Book (6)
- conference proceeding (summary) (3)
- conference proceeding (volume) (3)
- Doctoral Thesis (3)
- Report (3)
- Other (2)
- Bachelor´s thesis (1)
Language
- English (94)
- German (86)
- Multiple languages (2)
Publication reviewed
- begutachtet (157)
- nicht begutachtet (23)
Keywords
- KLEVERTEC / Vorlaufforschung (7)
- LILIPUT (7)
- Automatisierungstechnik (6)
- MEDAL (6)
- Produktionstechnik (6)
- ARCHIVE (5)
- DrGaN (5)
- Künstliche Intelligenz (5)
- Digitaler Zwilling (4)
- Lehre (4)
Institute
- Fakultät Maschinenbau (69)
- Fakultät Elektrotechnik (56)
- EPT – Institut für Effiziente Produktionstechnik (25)
- IMS - Institut für Maschinelles Sehen (23)
- KLEVERTEC (14)
- IPI – Institut für Produktion und Informatik (12)
- Fakultät Informatik (8)
- IEAT - Institut für Energie- und Antriebstechnik (6)
- ECC-ProBell - Europäisches Kompetenzzentrum für Glocken (4)
- IFA – Institut für Innovative Fahrzeugantriebe (4)
Algorithms for causal discovery have recently undergone rapid advances and increasingly draw on flexible nonparametric methods to process complex data. With these advances comes a need for adequate empirical validation of the causal relationships learned by different algorithms. However, for most real and complex data sources true causal relations remain unknown. This issue is further compounded by privacy concerns surrounding the release of suitable high-quality data. To tackle these challenges, we introduce causalAssembly, a semisynthetic data generator designed to facilitate the benchmarking of causal discovery methods. The tool is built using a complex real-world dataset comprised of measurements collected along an assembly line in a manufacturing setting. For these measurements, we establish a partial set of ground truth causal relationships through a detailed study of the physics underlying the processes carried out in the assembly line. The partial ground truth is sufficiently informative to allow for estimation of a full causal graph by mere nonparametric regression. To overcome potential confounding and privacy concerns, we use distributional random forests to estimate and represent conditional distributions implied by the ground truth causal graph. These conditionals are combined into a joint distribution that strictly adheres to a causal model over the observed variables. Sampling from this distribution, causalAssembly generates data that are guaranteed to be Markovian with respect to the ground truth. Using our tool, we showcase how to benchmark several well-known causal discovery algorithms.
Wide bandgap semiconductors, SiC and GaN-based power devices represent key candidates in the development of more efficient devices due to their superior electrical and thermal properties compared to silicon. To achieve maximal performance from WBG semiconductors, new packaging technologies and thermo-electric designs must be developed to ensure efficient and fast switching of devices while minimizing losses. The paper aims to investigate the thermal and mechanical behavior of new prepackage embedding technologies by finite element simulation. The focus is on insulated substrates including direct bonded copper (DBC) with various dielectrics such as AlN, Al 2O 3, Si3N 4 and new insulated metal substrates (IMS) with emphasis on commercially available materials and thicknesses. This study proposes a thermo-mechanical pareto-optimization methodology able to identify the best substrate configuration. The sintered silver layer (in both sides of the chip), which is the most prone to failure due to delamination, has been modelled with a temperature-dependent bilinear hardening model to account for plasticity. Pareto-optimization accounts for the module thermal resistance and the plastic strain or Von Mises Stress in the sintered layer. Results demonstrate that the best candidate from the thermo-mechanical point of view is the DBC with AlN showing a thermal resistance of 0.34 K/W, accumulative plastic strain of 0.18 % and Von Mises stress of 274 MPa. Finally, the parasitic inductance of multiple pre-packages is evaluated to scale the power of the module. Proper design allows to achieve a stray inductance as small as 1.23 nH for two prepackages and 2.85 nH for four prepackages.
Horizontal chip cracks have been reported in various scientific publications on PCB embedded power semiconductor devices. This study investigates in detail the root cause of the cracks. Experimental evidence indicates that the chip fractures in the mechanical grinding process during preparation of the cross-sections. Here, two different factors are relevant: First, the mechanical fracture strength of the semiconductor die decreases when grinding its edge. The use of P320 sand paper reduces the characteristic fracture strength from 719 MPa to 211 MPa. Second, the tensile stresses in the chip edge increase considerably when, part of the die and package is removed by grinding. Both effects together result in a failure probability of 100%. The use of finer grain sandpaper for target preparation helps to reduce the probability of generating horizontal chip cracks during cross-sectioning.
Die Veröffentlichung beleuchtet die Herausforderungen und Lösungsansätze zur Bekämpfung des Fachkräftemangels innerhalb der produzierenden Industrie am Standort Deutschland. Der Mangel an qualifizierten Arbeitskräften führt zu erheblichen Kosten und reduziert das Produktionspotenzial. Hauptursachen sind der demographische Wandel und veränderte Wertvorstellungen der Beschäftigten. Es gillt, das Arbeitsumfeld Produktion attraktiver zu gestalten, indem individuelle Beiträge sichtbarer gemacht und das Gemeinschaftsgefühl gestärkt werden. Zudem soll die wahrgenommene Komplexität reduziert und die Autonomie des Fertigungspersonals erhöht werden. Beispiele wie ein digitales Ampelsystem und die Visualisierung individueller Beiträge verdeutlichen diese Ansätze. Die Zukunft der Produktion wird durch sieben Thesen skizziert, die die Bedeutung einer partizipativen Planung, die Veränderung der Anforderungen und die Notwendigkeit eines Kommunikationsraums betonen. Die Präsentation endet mit der Vision einer modernen, vollvernetzten und arbeitnehmerfreundlichen Produktionsstätte.
Many cities in Europe and around the world are concerned with reducing their CO2-emissions. One step on this agenda is the introduction of electric buses to replace combustion engines. The electrification of urban buses requires an accurate prediction of the energy demand. In this pa per, an energy model and the underlying calibration process is presented. This approach leverages substantial tracking data from 10 electric buses operated in Göttingen, Germany. It was shown that, with the use of additional information from the directly measured tracking data, like auxiliary power, charging power and vehicle weight, it is possible to precisely calibrate models based on physical equations with regard to generally poorly identifiable parameters like rolling friction coefficient or efficiency of the electric machine. With a multilayered approach for simulating the energy demand, it is possible to validate the results on the mechanical layer and on the electrical layer separately. This enables a far better parametrization and elimination of uncertainties from the different parameters. Furthermore, we compare the results to other publications for sections with 1 km, 100 km and 230 km, respectively. The relative errors between the simulated and measured electrical power consumption are below 0.3%, 3% and 6.5%, respectively. Hence, the yielded model is appropriate for electric urban bus network planning applications. And the found parameters should be a good starting point for other energy prediction models. To further enable comparability with other approaches the dataset used for calibration is made publicly available.
Many cities in Europe and around the world are concerned with reducing their CO2-emissions. One step on this agenda is the introduction of electric buses to replace combustion engines. The electrification of urban buses requires an accurate prediction of the energy demand. In this pa per, an energy model and the underlying calibration process is presented. This approach leverages substantial tracking data from 10 electric buses operated in Göttingen, Germany. It was shown that, with the use of additional information from the directly measured tracking data, like auxiliary power, charging power and vehicle weight, it is possible to precisely calibrate models based on physical equations with regard to generally poorly identifiable parameters like rolling friction coefficient or efficiency of the electric machine. With a multilayered approach for simulating the energy demand, it is possible to validate the results on the mechanical layer and on the electrical layer separately. This enables a far better parametrization and elimination of uncertainties from the different parameters. Furthermore, we compare the results to other publications for sections with 1 km, 100 km and 230 km, respectively. The relative errors between the simulated and measured electrical power consumption are below 0.3%, 3% and 6.5%, respectively. Hence, the yielded model is appropriate for electric urban bus network planning applications. And the found parameters should be a good starting point for other energy prediction models. To further enable comparability with other approaches the dataset used for calibration is made publicly available.
Produkte werden heutzutage immer variantenreicher und individueller. Für die industrielle Fertigung wachsen die Anforderungen, die Produkte effizient zu fertigen und schnell auf sich verändernde Marktbedingungen zu reagieren. Entsprechend rapide steigt die Nachfrage nach flexiblen Produktionslösungen, die sich möglichst autonom an die neuesten Marktanforderungen anpassen. Wandlungsfähige und modulare Produktionssysteme sollen es ermöglichen, auch bei großer Variantenvielfalt effizient zu produzieren - sogar bis zur Losgröße 1. Unterstützt wird die Produktion durch digitale Lösungen, die bereits an vielen Stellen zum Einsatz kommen.
Der Arbeits- und Fachkräftemangel wird seitens der produzierenden Industrie im DACH-Raum als zunehmend wachstumshemmend und geschäftsmodellbedrohend empfunden. Als zentrale Ursachen können gleichermaßen der demographische Wandel wie auch ein entsprechender Wertewandel ausgemacht werden. Es erscheint daher empfehlenswert, die "Ressource Mensch" in dieser Gemengelage neu zu denken. Die Frage, wie ein modernes Produktionssystem beschaffen sein muss, damit dieses aus Arbeitnehmersicht langfristig als attraktiv wahrgenommen wird, rückt hierbei in den Mittelpunkt wissenschaftlicher Überlegungen.
„Hybride Montage“ als Antwort auf Modell Mix und Variantenvielfalt im produzierenden Mittelstand
(2024)
Die "Hybride Montage" als Kombination aus konventioneller Fließfertigung und innovativer Matrixproduktion offeriert vielfältige Potentiale, dem zunehmenden Maß an Variantenvielfalt in der produzierenden Industrie Rechnung zu tragen. Im Zeitalter des Industrial Metsverse und der damit verbundenen "Servitisierung" und des "Manufacturing as a Service" - d.h. der Güterproduktion als Dienstleistung - ermöglicht die Hybride Montage außerdem eine flexiblere Arbeitsplanung.
Durch globale Unsicherheiten, steigende Variantenvielfalt und den Kundenbedarf nach ökologisch nachhaltig produzierten Produkten nehmen die Anforderungen an heutige Produktionssysteme stetig zu. Dies stellt bisherige Produktionsformen wie die Linienproduktion zunehmend vor Herausforderungen. Als hochflexible Produktionsform bietet sich die Matrixproduktion als alleinige oder in Kombination mit der Linie als hybride Produktionsform an.
Die produzierende Industrie des DACH-Raumes erlebt im Jahr 2023 vielfältige Herausforderungen. Gerade scheint die Covid-Pandemie überwunden, welche die Vulnerabilität globaler Lieferketten schonungslos offenbart hat, treten neue Herausforderungen zutage. Veränderungen der gesetzlichen Anforderungen (wie EU Data Act), steigende Ansprüche an ökologische Nachhaltigkeit (z.B. Kreislaufwirtschaft) oder veränderte Kundenbedürfnisse (wie insbesondere Servitisierung) führen – bei einem konstant hohen Niveau an Variantenvielfalt – zu erheblichen technologischen Herausforderungen. Diese werden darüber vielerorts flankiert und im negativen Sinne überlagert durch einen erheblichen Mangel an Arbeits- und Fachkräften in der Produktion. Das Produktionssystem der Zukunft wird unserer Einschätzung nach daher nicht nur unternehmensübergreifenden Datenaustausch ermöglichen, Kreislaufwirtschaft befähigen und verstärkt kundenzentriert ausgerichtet sein. Es wird Arbeits- und Fachkräfte in der Produktion auf vielfältige Art und Weise „begeistern“. Auf diese Weise wird Fluktuation reduziert, generisches Wissen im Unternehmen gehalten und so die Grundlage für nachhaltigen Geschäftserfolg und technologischen Fortschritt sowie die langfristige Sicherung von attraktiven Arbeitsplätzen in der produzierenden Industrie geschaffen.
Nach unserer Überzeugung setzen sich in der produzierenden Industrie des DACH-Raumes diesbezüglich zwei Erkenntnisse durch:
1. Der „kritische Wettbewerb“ stammt selten aus Europa
2. Für die Bewerkstelligung dieser Herausforderungen sind authentische Impulse von außen – insbesondere von anderen, vergleichbaren Unternehmen – ein zentraler Erfolgsfaktor.
In dieser Gemengelage haben wir mit dem SUMMIT ALLGÄU eine Managementkonferenz „von der Industrie für die Industrie“ ins Leben gerufen. Im Zentrum des Veranstaltungskonzeptes stehen hierbei keine wissenschaftlichen Fachvorträge, sondern authentische Erfahrungsberichte hochkarätiger Referenten aus der industriellen Praxis. Beim ersten SUMMIT ALLGÄU Produktion am 23. und 24. Oktober 2023 in Marktoberdorf standen inhaltlich insbesondere die Themenkomplexe „Transformation & Nachhaltigkeit“, „Faktor Mensch in der Produktion“ sowie „Variantenvielfalt“ im Fokus. Auf überfachlicher Ebene wurden vor allem der persönliche Austausch und das Networking zwischen den zahlreichen Teilnehmern, Referenten und Ausstellern fokussiert.
The spectrometer-free chromatic confocal measurement technique enables 3D surface measurements with just one exposure and without scanning. To reduce the need for a spectrometer for the spectral analysis of the reflected light composition and thus the extraction of the local surface height, an optical spectral analysis unit is used. This unit determines the first momentum of the spectral composition reflected from the surface under probe for a large number of lateral measurement points simultaneously. This work investigates the impact of the spectral composition and light power of the light source on the sensitivity and accuracy of this method. A thorough optimization of the light source will be conducted, demonstrating the impact of various spectral compositions and light source power on the system performance, taking into account the system-related etendue. In addition, the optimization of the spectral transmission filter used in the optical spectral analysis unit and its influence on the accuracy and sensitivity of the system over the entire measurement range is shown.
The spectrometer free areal chromatic confocal metrology (ChromaCAM) is an optical 3D surface measurement technology, which allows a simultaneous measurement of a large array of measuring points within a single exposure. In this work, we investigate the accuracy of a first prototype sensor system utilizing this new singleshot 3D measurement technique. It is found that surface height measurement errors smaller 1μm within a total measurement range of about 1000 μm are achievable. Furthermore, several influential factors are investigated showing the advantages and limits of the presented system. Investigating different surface materials it is found that frame rates up to approximately 800 fps for highly reflecting surfaces and up to 30 fps for ceramics, aluminum, and plastics are achievable.
Portable Emission Measurement Technology and RDE on Motorcycles as Instruments for Future Challenges
(2020)
A considerable amount of enabling technologies are being explored in the era of fifth generation (5G) mobile system. The dream is to build a wireless network that substantially improves the existing mobile networks in all performance metrics. To address this 5G design targets, massive MIMO (multiple input multiple output) and mmWave (millimeter wave) communication are also candidate technologies. Luckily, in many respects these two technologies share a symbiotic integration. Accordingly, a logical step is to integrate mmWave communications and massive MIMO to form mmWave-massive MIMO which substantially increases user throughput, improve spectral and energy efficiencies, increase the capacity of mobile networks and achieve high multiplexing gains. Thus, this work analyses the concepts, performances, comparison and discussion of these technologies called: massive MIMO, mmWave Communications and mmWave-massive MIMO systems jointly. Besides, outcomes of extensive researches, emerging trends together with their respective benefits, challenges, proposed solutions and their comparative analysis is addressed. The performance of hybrid analog-digital beamforming architecture with a fully digital and analog beamforming techniques are also analyzed. Analytical and simulation results show that the low-complexity hybrid analog-digital precoding achieves all round comparable precoding gains for mmWave-Massive MIMO technology.
Das Industrial Metaverse scheint der nächste große Game Changer in der modernen Industrie zu werden und wird diese signifikant verändern. Die Vision ist nicht nur die Simulation einer einzelnen Anlage, wie sie Unternehmen heute beispielsweise bei der virtuellen Inbetriebnahme einsetzen, sondern ganzheitlicher Anlagenverbunde aus heterogenen Maschinen samt Fabrikperipherie und Infrastruktur – einer Digitalen Fabrik. Um das Industrial Metaverse zum Leben zu erwecken, wird eine Vielzahl zusätzlicher Technologien und Innovationen benötigt, als lediglich Digitale Zwillinge. Dieser Beitrag schlägt eine ganzheitliche Referenzarchitektur eines Industrial Metaverse vor und fokussiert auf dessen Nutzen.
The packaging of fresh meat has been studied for decades, leading to improved packaging types and conditions such as modified atmosphere packaging (MAP). While commonly used meat packaging uses fossil fuel-based materials, the use of biodegradable packaging materials for this application has not been studied widely. This study aimed at evaluating the sustainability of biodegradable packaging materials compared to established conventional packaging materials through analyses of the quality of freshly packaged pork. The quality was assessed by evaluating sensory aspects, meat color and microbiological attributes of the pork products. The results show no significant differences (p > 0.05) in ground pork and pork loin stored in biodegradable MAP (BioMAP) and conventional MAP for the evaluated sensory attributes, meat color or total bacterial count (TBC) over extended storage times. The data suggest that BioMAP could be a viable alternative to MAP using conventional, fossil fuel-based materials for the storage of fresh meats, while simultaneously fulfilling the customers’ wishes for a more environmentally friendly packaging alternative.
The dissertation presents two approaches for novel and improved measurement techniques, in the area of optical confocal surface metrology.
Firstly, a highly miniaturized endoscopic point distance sensor based on a spatial confocal measurement principle is presented. The sensor utilizes a new technique called spatial confocal point distance measurement. A special feature of the proposed sensor design is the high degree of miniaturization through femto-second direct laser writing and the use of optical fiber bundles, which enable an endoscopic application.
The second part of the dissertation will present a novel method for chromatic confocal metrology, that enables high-speed and high-resolution one-shot areal surface metrology without the need for a spectrometer. After deriving the theoretical basis of the approach, an optical design is conducted and verified using a preliminary optical simulation, After the design of a suitable housing and implementation of a calibration and processing algorithm, the experimental validation and the acquired results will be presented.
In summary, this work adds two novel measurement techniques to the field of fast in-line optical confocal metrology.
This study investigated the thermal performance of a packaging solution designed to manage the electrical isolation and cooling of high voltage ( ) SiC power semiconductor > 3300 V devices. The proposed packaging merges the ceramic substrate and the heat exchanger into a single component, streamlining the overall design. Specifically, a novel heat exchanger is developed for a multi-chip module (20 kV), utilizing a combination of jet impingement and channel- flow cooling techniques. Computational fluid dynamics (CFD) simulations and experimental validation are conducted on a multi-chip module to assess the thermal resistance of this new cooling solution. The results demonstrate a
low thermal resistivity of 0.118 cm2K/W, indicating the potential for improved cooling performance in high voltage and power density semiconductor applications.
Battery electric buses (BEBs) are gaining prominence in public transportation systems. In this paper, we investi-gate the impact of road grade, passenger load, and recuperation power limits on the energy consumption of BEBs using a physics-based model with tuned parameters. The model was employed to conduct a sensitivity analysis taking into account different altitude data sources, passenger load assumptions, and maximum recuperation power limits. The results highlight the importance of considering the route topology and its interaction with dynamic passenger loading for energy consumption predictions. Further-more, the results indicate that various altitude data sources are feasible to estimate the road grade for this purpose. Apart from that, the sensitivity for recuperation power limitations is shown and put into context. Within a broader framework, the findings suggest that physics-based energy consumption models with optimised parameters can serve as a powerful tool for enhanced operations and planning of BEBs.
Various software environments have been developed in the past to create digital twins of single cells or a digital twin of a factory. Each environment has its own strengths and weaknesses and has been designed with a specific focus. The environments that are able to holistically simulate complete factories are limited in terms of the modelling details required for the analysis of single manufacturing cells (e.g., manufacturer-independence of the individual digital twins) and their ability for virtual commissioning. This paper presents three options for realising a virtual commissioning of linked cells using a 3D integration platform with NVIDIA Omniverse, consisting of two different digital models fused into a combined model, also representing material flow. First, with a source/sink solution and unidirectional connector controlled by OPC UA; secondly, with a bidirectional connector, developed in the course of this elaboration, and an extension of the 3D integration platform controlled by Apache Kafka; thirdly, with a bidirectional connector and using only an extension of the 3D integration platform. The research demonstrates that virtually commissioning multiple linked digital twins from different manufacturers in a 3D platform with material flow makes a significant contribution to the industrial metaverse.
In der vorliegenden Arbeit werden Methoden zur datengetriebenen Qualitäts- und Verschleißbestimmung beim Scherschneiden entwickelt. Zunächst wird ein optisches Überwachungssystem in einen Scherschneidprozess integriert und eine Inline-Überwachung in Bezug auf die Schnittflächenkenngrößen ermöglicht. Für die automatische Qualitätsbestimmung wird am Beispiel der Glattschnitthöhe ein Algorithmus zur automatisierten Bildverarbeitung gezeigt. Die neuen Möglichkeiten, die durch diese Entwicklung entstehen, werden anhand einer Fallstudie analysiert. Um die Schwächen des entwickelten Algorithmus mit Blick auf die Verarbeitungszeit auszugleichen, werden ebenfalls neuronale Netzwerke zur Bildverarbeitung untersucht. Zunächst wird hierzu eine Datenmenge aus dem Fertigungsprozess aufgezeichnet und ein manuelles Labelling sowie eine künstliche Datenerweiterung durchgeführt. Beruhend auf Normen und Expertenwissen, wird eine Methode zur Bewertung der Prognosegüte entwickelt. Diese beinhaltet eine Bewertung anhand von verschiedenen Koeffizienten, die sowohl konturbasierte als auch regionenbasierte Ansätze kombinieren. Durch einen Vergleich unterschiedlicher Netzwerkarchitekturen zur Bildsegmentierung und deren Optimierung wird eine Netzwerkarchitektur ermittelt, die die Qualitätsbewertung im Hinblick auf die Glattschnitthöhe innerhalb des Fertigungsprozesses ermöglicht.
Abschließend wird ein Sensornetzwerk bestehend aus unterschiedlichen Sensoren und dem entwickelten Überwachungssystem an einem Scherschneidprozess installiert. In einer Versuchsreihe werden Daten der unterschiedlichen Datenquellen über die Lebensdauer eines Schneidstempels aufgezeichnet. Zusätzlich wird zu definierten Intervallen der vorliegende Schneidstempelverschleiß ermittelt. Die Daten werden in Verschleißklassen eingeteilt und durch unterschiedliche Datenvorverarbeitung entstehen mehrere Merkmalsräume. Diese unterscheiden sich zum einen durch die Kombination der Datenquellen als auch durch die angewendete Datenreduzierung. Die unterschiedlichen Merkmalsräume dienen zum Training von sowohl klassischen Algorithmen des maschinellen Lernens als auch neuronalen Netzwerken. Eine Bewertung und Analyse erfolgt anhand der jeweiligen Konfusionsmatrix und mittels SHAP-Werten. Es zeigte sich, dass durch eine Vorhersage der Verschleißklassen beruhend auf den Bildaufnahmen der Glattschnittfläche nur minimal schlechtere Ergebnisse erzielt werden als durch ein Sensornetzwerk beruhend auf einer Kombination aller Datenquellen.
Intensive research in the field over the past decades highlighted the complexity of aroma partition. Still, no general model for predicting aroma matrix interactions could be described. The vision outlined here is to discover the blueprint for the prediction of aroma partitioning behavior in complex foods by using machine learning techniques. Therefore, known physical relationships governing aroma release are combined with machine learning to predict the 𝐾𝑚𝑔 value of aroma compounds in foods of different compositions. The approach will be optimized on a data set of a specific food product. Afterward, the model should be transferred using explainable artificial intelligence (XAI) to a different food category to validate its applicability. Furthermore, we can transfer our approach to other relevant questions in the food field such as aroma quantification, extraction processes, or food spoilage.
Das Forschungsprojekt TwinMaP hat zum Ziel, eine effiziente Komplettbearbeitung von Bauteilen variabler Losgrößen in einem heterogenen Maschinenpark zu ermöglichen. Der wirtschaftlichste Produktionsablauf soll mittels digitalen Zwillingen, die mit den realen Anlagen und einer Integrationsplattform vernetzt sind, in einer Vorsimulation ermittelt werden.
Die Fertigungsindustrie orientiert sich derzeit in Richtung von Technologien, die Sprungbrettinnovationen in der Produktion ermöglichen. In diesem Zusammenhang werden häufig das Industrial Metaverse und die Künstliche Intelligenz (KI) genannt. In diesem Artikel werden erste Implementierungen dieser Technologien und aktuelle Forschungsaktivitäten im Produktionsumfeld vorgestellt.
The Industrial Metaverse (IM) is an upcoming topic for companies and offers new possibilities to digitalize and optimize their business processes together with AI capabilities. In the production domain, the Industrial Metaverse is a step towards the vision of predicting factory behavior for optimization purposes. A central challenge is a complete factory model necessary as the base to predict its behavior. Therefore, the IM approach is promising to build and contain this model out of available single Digital Twins of factory parts. Consequently, an IT target landscape is required to build an Industrial Metaverse for Digital Twins. This paper evaluates different design pattern options for an industrial IT architecture reference implementation of an IM that companies can use in current IT landscapes. It also proposes a high-level roadmap towards the proposed target IT architecture of an IM.
Tests are carried out on two different series-connected switches made of six SiC MOSFETs capable of blocking 10 kV and 20 kV respectively. High voltage capacitors are connected to the drain terminals of the MOSFETs to emulate the common mode currents’ paths due to parasitic capacitances of the packaging. Due to high dV/dt, common mode currents become dangerous to the switch as they unsettle the voltage sharing during turn-off and unbalance switching losses. This could lead some of the MOSFETs to experience avalanche breakdown. A novel packaging approach that suppresses or balances the common mode currents is introduced.
Gallium nitride transistors have a smaller die area compared to silicon-based devices, which can lead to thermal challenges in high current density applications. Therefore, thermally optimized packages with a high heat spreading capability in combination with small parasitic are necessary. This work investigates the thermal performance a 7 mΩ, 100 V GaN HEMT in a thermally optimized single chip package with integrated RTD and compares it to the commercial counterpart. The thermal optimized package shows a significantly better transient thermal impedance resulting in a static thermal resistance of 3.1 K/W, which is a 20 % reduction in comparison to the COTS package. The integrated RTD trace has a relative reaction time of 590 ms, which is 30-fold slower in comparison to the junction temperature. To show the identical electrical behavior, although the single chip package is larger, it is compared with the commercial off-the-shelf package and a 5 mΩ, 100 V GaN single chip package in a 300 kHz, 48 V buck converter. Both 7 mΩ versions have identical efficiencies of ≈97.5 % up to 50 A output current, slightly outperforming the 5 mΩ GaN transistor. With its combination of improved thermal characteristics and lowinductance, the thermally optimized package of the GaN device offers more degrees of freedom in the design of power converter to exploit trade-offs between longer lifetime, higher temperature operation and power density. Index Terms—gallium nitride, high electron mobility transistor, (thermal) performance evaluation, thermally optimized package, DC/DC converter, high current application, parallelization
In diesem Beitrag wird ein Manipulatormodell zur Verwendung in einem Entwurfsprozess für die Manipulatormechanik vorgestellt. Das Ziel ist Schwingungen zu minimieren und die Genauigkeit applikationsspezifisch zu entwerfen. Aus geeigneten Modellansätzen der einzelnen Roboterkomponenten, wie der Tragstruktur, den Wälzlagern, der Verkabelung und der Fügestellen wird ein Gesamtmodell einer seriellen Sechs-Achs-Kinematik in Modelica erstellt. Für den Antriebsstrang werden Modellansätze für Kompaktgetriebe, Riementriebe, Wellen und Zahnräder abgeleitet. Eine Validierung erfolgt durch eine Modalanalyse durch Selbstanregung.
使工厂生产更灵活的创新
(2023)
Die wichtigsten Elemente von Industrie 4.0 auf der Feldebene sind Aktoren und Sensoren. Durch den Einsatz von Sensoren und Aktoren in Verbindung mit einer bestehenden Infrastruktur und basierend auf der Internettechnologie wird eine Automatisierung und Überwachung der Prozesse ermöglicht. Sensoren dienen dabei als Datenlieferant, Aktoren sind die ausführende Hardware. Die Zielsetzung „Losgröße 1“ von Industrie 4.0 erfordert schnellste Datengenerierung und Umsetzung in Aktionen. Als „Smart Field Devices“ erhalten sie mehr lokale Verarbeitungskapazität. Es geht aber nicht nur um die dezentrale Datenverarbeitung, sondern Innovationen sind auch im Bereich der Basisfunktionen relevant. Bei den Aktoren sind Innovationen auf der Basis der Piezo-Keramik aufzuführen, speziell für Industrie-4.0-Anforderungen sind es Innovationen wie z.B. flexible Bewegungssysteme für Roboter. Auch auf der Sensor-Seite sind neue Basisfunktionen zu entwickeln, im Zusammenhang mit einer zunehmenden Miniaturisierung und Multi-Sensor-Systemen. Unabdingbar für Sensoren wie Aktoren ist die Einbindung in die Daten- und Informationsvernetzung, die über verschiedene Ebenen hergestellt werden muss. Für diese „Field Device Integration (FDI)“ stehen anerkannte Protokolle zur Verfügung, die einen Datentransfer der verschiedensten Geräte ermöglichen. Hier besteht noch ein Entwicklungsbedarf, bestehende Aktoren und Sensoren mit entsprechenden Schnittstellen hierfür auszurüsten.
Die Verfügbarkeit von Produktionsdaten ist eine zentrale Herausforderung der zerspanenden Industrie. Herstellern von Maschinen, Maschinenbauteilen und Sensoren fehlt es an Informationen über das Verhalten ihrer Produkte im Einsatz, um Optimierungspotenziale zu erkennen. Im Fokus des Forschungsprojektes Dione-X stehen daher der sichere und souveräne Datenaustausch entlang der Wertschöpfungskette und die Entwicklung von datengetriebenen Geschäftsmodellen.
In general, current systems for the Digital Factory implement a product-process-resource (PPR) data model in a monolithic rich-client/server architecture with a single database persistence layer. Common data objects are the product bills of material, descriptions of the production processes, or the resource structure, e.g. bill of equipment. The main drawback of the current monolithic architecture is the slow rate of development, which prevents fast adoption of the software to the new production planning process (i.e., due to new technologies for the transformation of the automotive industry with the goal of electrification) is not possible. Furthermore, time-consuming and error-prone export-import operations characterize the collaboration of the engineering supply chain. Mercedes-Benz has created a new IT system architecture for their Digital Factory. The core idea of this architecture is a module-based approach. Each planning step has its own module, e.g. product analysis, layout planning or cost calculation. One single module consists of a server-based business logic, a web-based user interface and its own database. Each module is the source of master data objects that originate from the corresponding planning step and refers to data objects from predecessor planning steps. The single modules communicate mostly via KAFKA. The usage of a model based application engine allows the fast creation of different modules. Best-of-breed third-party systems for specific planning steps can be integrated into the system architecture. Web technologies allow suppliers to access the Mercedes-Benz systems directly for a fully integrated supplier collaboration. Roll-out has started and has already led to significant efficiencies.
Die mittelständisch geprägte deutsche Gießereibranche steht vor akuten
Herausforderungen. Steigende Energie- und Rohstoffpreise wirken sich als Standortnachteil aus und erhöhen den Druck, die Effizienz der Produktion weiter zu erhöhen. Probleme bei der Rekrutierung qualifizierter Fachkräfte erfordern neue Ansätze zur Sicherung des Prozesswissens erfahrener Mitarbeiter. Zudem fehlt aufgrund der mangelnden analytischen Beschreibbarkeit und der Komplexität der Prozesse häufig eine adäquate Modellierung der Kausalketten, was die Ursachenforschung bei Qualitätsproblemen erschwert.
Datenbasierte multimodale Assistenzsysteme können gewinnbringend in
Gießprozessen eingesetzt werden und einen Teil dieser Probleme lösen. Sie nutzen fortgeschrittene Methoden der Datenanalyse (Data Analytics), ein Prozess der Datenuntersuchung, des Datenverständnisses und des Erkenntnisgewinns, in dem unbekannten Muster und Zusammenhänge zwischen den Variablen durch die Analyse von Rohdaten identifiziert werden. So können komplexe Prozesse modelliert, Probleme frühzeitig erkannt und Lösungen in Echtzeit generiert werden. Viele Softwaretools und Datenbanken unterstützen bereits heute die sogenannte „deskriptive Analyse“ und die „diagnostische Analyse“. Ein weiterer Schritt ist jedoch, dieselben Daten zu nutzen, um Modelle zu speisen, die Vorhersagen mit ähnlicher oder besserer Genauigkeit als ein menschlicher Experte treffen können (prädiktive Analyse).
Punching is a process that is sensitive to a multitude of parameters. The estimation of part and punch quality is often based on expert knowledge and trial-and-error methods, mostly carried out as a separate offline process analysis. In a previous study, we developed an optical inline monitoring system with subsequent image processing which showed promising results in terms of capturing every manufactured part, but was limited by slow image processing. Here, we present a more efficient image processing technique based on neural networks. For our approach, we manually identify the burnish parts in images based on criteria established via an expert survey in order to generate a training dataset. We then employ a combination of region-based and boundary-based losses to optimize the neural network towards a segmentation of the burnish surface which allows for an accurate measurement of the burnish height. The hyperparameter optimization is based on custom evaluation metrics that reflect the requirements of the burnish surface identification problem as well. After comparing different neural network architectures, we focus on optimizing the backbone of the UNet++ structure for our task. The promising results demonstrate that neural networks are indeed capable of an inline segmentation that can be used for measuring the burnish surface of punching parts.
Kompaktes Lehrbuch für Studium und Praxis.
Dieses Lehrbuch für Studium und Praxis ist speziell abgestimmt auf das Ingenieurwesen, das Wirtschaftsingenieurwesen und die Betriebswirtschaft. Es wird ein breites Wissen über die wesentlichen Elemente des Qualitätsmanagements dargestellt: vom Qualitätsmanagement in der Beschaffung, der Statistik, den Messsystemen, der ISO 9001, den Qualitätsmethoden, bis hin zum Projekt- und Risikomanagement und der Servicequalität. Zudem wird ein Schwerpunkt auf das internationale Qualitätsmanagement gelegt. Zentral sind kommunikative und interkulturelle Kompetenzen – sei es beim Umgang mit Fehlern, bei der Lösungssuche oder beim Aufbau eines Qualitätsmanagementsystems.
In order to enable the packaging-free purchase of highly viscous foodstuffs requiring refrigeration (such as dairy products), the Kempten University of Applied Sciences developed a dosing dispenser for this area of application and built it with the aid of additive manufacturing processes. The main requirements were to ensure functionality, i.e. sufficient cooling capacity and reliable, hygienic dosing of the products to be filled, as well as easy handling by the customers. Furthermore, a modular system was to be developed that would allow different product categories from quark to yogurt to be filled. With the equipment concept developed for this purpose, different configurations can be flexibly combined and easily exchanged via a modular system. Scalability of the product chamber was also demonstrated by developing a series.
Following a proof of concept, a virtual prototype of the food fill system was created and optimized. Based on this, a physical prototype was successfully realized and presented to potential target groups in field tests. In these user tests, both the required functionality under real test conditions and the acceptance by the respective target group were successfully confirmed.
The energy absorption capacity of braided composite frames under bending loads was studied by conducting quasi-static four-point-bending tests. As specimen geometry C-shaped frame segments where chosen which show the typical failure behaviour of frames with open cross section, such as local buckling and crippling. The braiding manufacturing process offers the possibility to influence the fracture mechanics by a local hybridization of the braider yarns. Different hybridization concepts were investigated to identify design principles for braided frame structures with enhanced energy absorption capacity. The test results show that the post-failure energy absorption of braided frame segments can be significantly increased by a local modification of the braid architecture.
A successful application of braiding technology for the manufacturing of an industrial product is shown on the example of a carbon fiber-reinforced plastic (CFRP) manipulator. Due to its lightweight design, the CFRP system offers highly ergonomic advantages for the worker compared to the previously available steel version. In the course of the braided manipulator design, braid-specific manufacturing options were used to improve bending and torsion stiffness by combining design aspects and fiber architecture variations. It is also shown how braid-related manufacturing constraints can be overcome by additional subsystems, eg, to realize strongly curved part geometries. Finally, a process of the mechanical testing procedure for the whole system is presented which follows the classical building-block approach used for the validation of aeronautical structures.
Breaking down the cost structure of state-of-the-art CFRP part shows that a major share of the costs is caused by labor and equipment as well as process energy consumption.
Therefore, the main goal of the EU funded FP7 project LOWFLIP (Low Cost Flexible Integrated Composite Process) has been the reduction of these costs by introducing new technologies into CFRP production processes.
The LOWFLIP concept focuses on three main aspects:
• Development of a new out-of-autoclave (OOA) prepreg system with snap cure capabilities.
• Development of a direct 3D placement technology for plies and tapes.
• Development of energy efficient and fast heating toolings.
The main content of this paper is detailed information on a novel direct 3D prepreg layup process for automated production of large-scale fiber reinforced parts of small and medium lot sizes. The advanced ply placement process, which is able to drape and compact unidirectional prepreg tapes with currently up to 300 mm ply width directly into a double curved tooling, is being introduced. Two large-scale demonstrator parts from the transport and aerospace sector will be presented. Experiences gained during prototype manufacturing will be reflected and benchmarks of the equipment are presented.
The effect of the cover factor on the in-plane mechanical properties of biaxial and triaxial braided carbon fiber composites is investigated. Low braid coverage occurs if the mandrel circumference exceeds a specific length, so that gaps occur in between the different yarn systems.
Braids are manufactured on different mandrel sizes with a braid angle of ±45°. The cover factor is calculated analytically and measured by means of gray scale analysis of scanned samples. A new analytical model is presented which allows for calculating the cover factor of triaxial braids in good approximation with real results, taking into account the off-centered alignment of the axial yarns. Tensile and compression test results are presented for the thermoset resin systems EPIKOTE MGS® RIM 235 and HexFlow® RTM6. The results show that there is a significant influence of decreased cover factors on the mechanical properties, especially in case of triaxial braids tested in axial direction. Micro computed tomography images based on synchrotron radiation reveal that low coverage leads to an increased fiber undulation of the axial yarns, which mainly determine the mechanical properties of triaxial braids. An influence of the different resin systems is observed for matrix-dominated properties of biaxial braids, where the composite failure strain is in the range of neat resin failure strain.
Scope of the presented work is a detailed comparison of a macroscopic draping model with real fibre architecture on a complex non-crimp-fabric preform using a new robot-based optical measurement system. By means of a preliminary analytical process design approach, a preforming test centre is set up to manufacture dry non-crimp-fabric preforms. A variable blank holder setup is used to investigate the effect of different process parameters on the fibre architecture. The real fibre architecture of those preforms is captured by the optical measurement system, which generates a three-dimensional model containing information about the fibre orientation along the entire surface of the preform. The measured and calculated fiber orientations are then compared with the simulation results in a three-dimensional overlay file. The results show that the analytical approach is able to predict local hot spots with high shear angles on the preform. Macroscopic simulations show a higher sensitivity towards changes in blank holder pressure than reality and limit the approach to precisely predict fibre architecture parameters on complex geometries.
Carbon fiber reinforced plastics (CFRP) allow to redesign well established metallic structures like manipulators in order to decrease their weight and to increase their level of performance. This task can only be successful, when the CFRP-design process does not copy the metallic structure, but solves the underlying functions in a new way. The present study shows, how an I-beam steel manipulator was transferred to a braided design with hollow cross sections and locally adapted material properties. Step by step we show, how to define the manipulator’s functions and mechanics and how they can be considered with a braided CFRP-structure. This includes analytical pre-design as well as detailed finite element method (FEM) design. A mechanical testing program was performed in order to measure input-values for the numerical calculations on coupon-level and validate the simulation on system level. Static and dynamic tests of the CFRP-manipulator showed that it fulfils all requirements to be certified for sale. Therefore, the braiding process for commercial production was investigated for two machine setups and the state of serial production was reached. The braided CFRP-manipulator is 70% lighter than the steel reference and has increased handling properties because of locally adapted material properties.
Ziel der vorliegenden Arbeit ist die Entwicklung eines messtechnischen Verfahrens, um prozessbedingte Variationen der Faserarchitektur textiler Preforms im Entwicklungsprozess von Bauteilen aus Faser-Kunststoff-Verbunden berücksichtigen zu können. Anhand mechanischer Prüfreihen von geflecht- und gelegeverstärkten Verbundwerkstoffen können klare Wirkzusammenhänge zwischen visuellen Textilmerkmalen und den mechanischen Eigenschaften identifiziert werden. Schwerpunkt der Untersuchungsreihen sind Auswirkungen von Lücken, Ondulationen und Streuungen des Faserwinkels auf die Zug- und Druckeigenschaften kohlenstofffaserverstärkter Kunststoffe. Die Erkenntnisse fließen in die Entwicklung eines optischen Messsystems zur 3D-Preformanalyse ein, welches mittels grauwertbasierter Bildverarbeitung die vollflächige Texturanalyse komplexer, dreidimensionaler Oberflächen ermöglicht. In der Arbeit werden zuletzt Anwendungspotenziale der detaillierten Faserarchitekturanalyse zur Optimierung von Fertigungsprozessen und zur Bauteildimensionierung vorgestellt.
This work describes why additive manufacturing is a key technology for efficient design iterations and rapid production ramp-up with large-scale manufacturing technologies. Laser cutting, injection moulding and folding were used to increase the production capacity of face shields for health care workers during the COVID-19 pandemic. We applied systematic learnings from the iterative processes used for additive manufacturing to these large-scale manufacturing technologies and the respective face shield designs. In cooperation with medical experts, structural and functional design requirements of face shields were identified and are described in detail in this work. The regulatory design requirements according to EN 166 are introduced, which were considered to receive a CE certification for three of the presented designs. The employed manufacturing techniques are specified and the respective implications on the design solutions are discussed. The paper concludes with a summary of the production initiative at the research campus ARENA2036 with a total output of over 13 000 face shields from April to June 2020, which were distributed internationally.
In case of electric vehicles (EV) powered by lithium ion traction batteries (LIB), remanufacturing processes nbecome increasingly important due to their rising market share and valuable raw materials. LIB can account for up to 40% of the total EV cost. Often, only a small portion of the cells are significantly degraded when the usable battery capacity falls below 80%, which is currently considered the standard end-of-life criterion. However, in order to enable efficient remanufacturing, novel battery design principles are required. This paper discusses the requirements, opportunities and challenges of future remanufacturing processes of LIBs down to the cell level using a battery system of a commercial vehicle as an example. It gives an overview of the current state-of-the-art manufacturing processes of battery systems and shows the developed overall remanufacturing process including condition assessment, disassembly and reassembly. Subsequently, requirements on future designs are discussed. The state-of-the-art of EV batteries is evaluated based on these requirements to determine where incompatible connections such as welded contacts or adhesive joints conflict with remanufacturing design principles.
Two large groups of materials, namely metals and ceramics, are used in mass quantities in today’s industry because of their outstanding properties. To achieve higher product performance dissimilar materials need to be combined in assemblies, but their joining is challenging. Using friction surfacing technology Al2O3 ceramic substrates were coated with an aluminium alloy (AlMg4.5Mn0.7). Earlier research by the authors suggested that two major bonding mechanisms, namely mechanical interlocking and van der Waals forces, are responsible for the bonding strengths achieved between the coating and the substrate. Further scanning electron microscopy, scanning transmission electron microscopy, high-resolution transmission electron microscopy and energy dispersive X-ray spectroscopy analysis at a sub nanometre resolution were conducted and are presented in this article. These analytical methods revealed that the aluminium coating and the Al2O3 grains form a sharp boundary without evidence of either a chemical reaction or diffusion at the interface and suggest that the main bonding mechanisms for the Al/Al2O3 system are van der Waals forces. In addition, mechanical interlocking may serve to hold in position the interface surfaces, to preserve their close proximity, allowing the van der Waals forces to persist.