TY - CHAP A1 - Galka, Stefan A1 - Meißner, Sebastian T1 - Simulation-Based Digital Twins for Internal Transport Systems T2 - Procedia Computer Science N2 - The increasing complexity of internal transport systems in industrial applications poses significant challenges for operational decision-making. This paper presents a simulation-based Digital Twin framework developed within the research project TwinTraSys to support the control of such systems. The framework is specifically tailored to the constraints of real-world IT infrastructures, requiring minimal transaction data, while enabling predictive analysis and dynamic scenario evaluation. It consists of a modular architecture divided into four core components: data provision, data preparation, simulation, and decision support. A dedicated simulation framework enables the automated generation of structural models and the integration of real-world operational control systems. The proposed approach has been validated in industrial settings and has demonstrated its ability to support resource planning and transport resource allocation through simulation-based experimentation and multi-criteria evaluation. This paper contributes to the practical advancement of Digital Twin applications in intralogistics by bridging the gap between theoretical models and real-world constraints. KW - Digital Twin KW - Intralogistics KW - Logistics KW - Operational Control KW - Simulation KW - Simulation-based Decision Support Y1 - 2025 U6 - https://doi.org/10.1016/j.procs.2025.12.016 N1 - Corresponding author der OTH Regensburg: Stefan Galka VL - 274 SP - 161 EP - 170 PB - Elsevier ER - TY - CHAP A1 - Schaeffer, Leon A1 - Schmaußer, Theresa A1 - Herrmann, David A1 - Lehmann, Lukas A1 - Dendorfer, Sebastian A1 - Böhm, Valter T1 - Multi-Body Simulation of a Dynamic Hand Orthosis based on a Prestressed Compliant Structure Incorporating the Human Hand T2 - 2025 International Symposium on Medical Robotics (ISMR), May 14-16, 2025, Atlanta, GA, USA, N2 - Many dynamic hand orthoses use one degree of freedom joints, such as hinge joints. Therefore, these orthoses can only partially replicate the complex, multi-axis movement of the hand. A possible solution for this is the use of prestressed compliant structures as the basis for orthoses. Determining the joint forces in the wrist and optimizing the dynamic orthosis to influence these forces as well as acting muscle forces are important steps in the development of these orthoses. For this reason, in this work multi-body simulation models of an orthosis with human hand models are presented. Based on these theoretical investigations, more detailed orthosis models as well as initial prototypes of prestressed compliant dynamic hand orthoses can be developed. KW - Hands KW - Wrist KW - Systematics KW - Simulation KW - Dynamics KW - Refining KW - Prototypes KW - Usability KW - Research and development KW - Testing Y1 - 2025 U6 - https://doi.org/10.1109/ISMR67322.2025.11025982 SP - 80 EP - 86 PB - IEEE ER - TY - CHAP A1 - Galka, Stefan A1 - Meißner, Sebastian A1 - Obermeir, Theresia ED - Fottner, Johannes T1 - Digitale Zwillinge für die Steuerung innerbetrieblicher Transportsysteme T2 - 32. Deutscher Materialfluss-Kongress 2025, Garching bei München, 20.-21.3.2025 N2 - Im Rahmen des Forschungsprojektes "Digitale(r) Zwillinge zur dynamischen Simulation für die Planung und Steuerung innerbetrieblicher Transportsysteme im Rahmen der digitalen Fabrik" (TwInTraSys) wurde ein simulationsbasierter Digitaler Zwilling zur vorausschauenden Entscheidungsunterstützung im operativen Betrieb von innerbetrieblichen Transportsystemen entwickelt. Das Konzept wurde demonstratorisch umgesetzt und bei verschiedenen Anwendungsunternehmen getestet und validiert. Im Folgenden werden die Einsatzmöglichkeiten im Zentrallager der Firma HiPP am Beispiel einer Ressourceneinsatzplanung dargestellt. KW - Innerbetrieblicher Transport KW - Simulation KW - Digitale Zwillinge Y1 - 2025 PB - VDI-Verlag ER - TY - BOOK A1 - Rill, Georg A1 - Schaeffer, Thomas A1 - Borchsenius, Fredrik T1 - Grundlagen und computergerechte Methodik der Mehrkörpersimulation BT - Vertieft in Matlab-Beispielen, Übungen und Anwendungen N2 - Dieses Lehr- und Übungsbuch vermittelt auf anschauliche Weise die Methoden der Mehrkörpersimulation und verdeutlicht deren Vor- und Nachteile bei der praktischen Anwendung anhand konkreter Beispiele. Die einzelnen Methoden werden durch Matlab-Skripte und -Funktionen verdeutlicht, wobei die Modellbildung, die mathematische Beschreibung und die numerische Simulation von Systemen starrer Körper die Schwerpunkte bilden. Die vorliegende Auflage wurde unter anderem um Matlab-Live-Skripte erweitert, welche kleine Animationen zur Veranschaulichung der Dynamik der Probleme enthalten. Die Lösungen zu den Übungsbeispielen und die integrierten Matlab-Skripte sowie weitere Beispiele und Anwendungen stehen über QR-Codes zum Download zur Verfügung und ermöglichen dadurch auch ein effizientes Selbststudium. KW - ADAMS-Modell KW - McPherson-Achse KW - Euler-Parameter KW - Bushings KW - Kontaktelement KW - Kinematische Bindung KW - Räumliches Doppelpendel KW - Analyse MKS KW - Lumped Mass Modelle KW - SIMPACK-Modell KW - Sparse Matrix KW - Mehrkörpersystem KW - MATLAB KW - Dynamik KW - Simulation Y1 - 2023 U6 - https://doi.org/10.1007/978-3-658-41968-4 PB - Springer Nature ER - TY - CHAP A1 - Galka, Stefan A1 - Schuhegger, Lukas ED - Feng, B. ED - Pedrielli, G. ED - Peng, Y. ED - Shashaani, S. ED - Song, E. ED - Corlu, C.G. ED - Lee, L.H. ED - Chew, E.P. ED - Roeder, T. ED - Lendermann, P. T1 - Integration of Discrete-event Simulation in the Planning of a Hydrogen Electrolyzer Production Facility T2 - Proceedings of the 2022 Winter Simulation Conference (WSC), 11-14 Dec. 2022, Singapore N2 - In the context of production and factory planning, the expansion of the factory must already be taken into account during initial planning. This results in an increase in planning complexity, as the involved planners have to know the expansion stages of the factory in the different time periods and have to evaluate concept modifications across all time periods. This paper presents an idea for a planning tool, which takes expansion stages into consideration. The data model contains all relevant information to generate a simulation model of the factory in an almost automated way. The aim is to enable factory planners to quickly investigate concept changes with the help of simulation, for example, to identify bottlenecks. KW - Simulation KW - Production KW - Digital Twin Y1 - 2022 UR - https://informs-sim.org/wsc22papers/pos114.pdf PB - IEEE CY - Singapore ER - TY - CHAP A1 - Haimerl, Simon A1 - Tschernitz, Christoph A1 - Schiller, Tobias A1 - Weig, Christoph A1 - Briem, Ulrich A1 - Galka, Stefan T1 - Development of a Simulation Framework for Urban Ropeway Systems and Analysis of the Planned Ropeway Network in Regensburg, Germany T2 - Proceedings of the 2022 Winter Simulation Conference (WSC), 11-14 Dec. 2022, Singapore N2 - To evaluate the performance of a ropeway in an urban environment, simulations of the dynamic passenger transport characteristics are required. Therefore, a modular simulation model for urban ropeway networks was developed, which can be flexibly adapted to any city and passenger volume. This simulation model was used to analyze the ropeway network concept of the German city Regensburg and to determine the expected operating conditions. The passenger volume, different types of persons, their occurrence probability and their destination distribution is depending on the location and daytime and can be defined for each individual station. In an initial analysis, the number of passengers currently occurring in bus traffic were projected onto the ropeway network. To enable climate-friendly and efficient operation, different strategies were developed to significantly reduce the number of gondolas. The best fitting strategies resulted in significant cost savings while passenger comfort, as represented by queue time, remained unchanged. KW - Simulation KW - urban mobility KW - ropeway Y1 - 2022 SN - 978-1-6654-7661-4 U6 - https://doi.org/10.1109/WSC57314.2022.10015510 SP - 1413 EP - 1424 PB - IEEE ER - TY - CHAP A1 - Schmid, Florian A1 - Wild, Tobias A1 - Schneidewind, Jan A1 - Vogl, Tobias A1 - Schuhegger, Lukas A1 - Galka, Stefan T1 - Simulation Based Approach for Reconfiguration and Ramp up Scenario Analysis in Factory Planning T2 - Proceedings of the 2022 Winter Simulation Conference (WSG), 11-14 Dec. 2022, Singapore N2 - Structural changes in production entail a potential economic risk for manufacturing companies. It is necessary to identify a suitable strategy for the reconfiguration process and to continue to meet the demand during the change in the factory structure and ramp-up phase. A simulation offers the possibility to analyze different ramp-up scenarios for the factory structure and to select a suitable concept for the reconfiguration process. A discrete event simulation approach is presented that can be used to evaluate variants of structural changes and serves as a basis for deciding on a reconfiguration strategy. This approach is demonstrated using a specific production step of a plant producing hydrogen electrolyzers, the results and generalized conclusions are discussed. KW - Simulation KW - Production KW - Ramp up Y1 - 2022 SN - 978-1-6654-7661-4 U6 - https://doi.org/10.1109/WSC57314.2022.10015310 SP - 2842 EP - 2852 PB - IEEE ER - TY - CHAP A1 - Galka, Stefan T1 - Untersuchung von Auftragsfreigabestrategien für mehrzonige Kommissioniersysteme im Online-Lebensmittelhandel T2 - ASIM SST 2022 Proceedings Langbeiträge, 26. ASIM Symposium Simulationstechnik: 25.07.-27.07.2022, TU Wien N2 - This paper briefly presents the challenges for order control and release of multi-zone order picking systems. On the one hand, the order control must ensure that all orders are processed on time, and on the other hand, the space requirements (buffer) and the utilisation of the zones must be considered. Within the framework of a case study, different strategies for order release were developed. The paper shortly describes the ideas of the strategies and presents results of a case-based simulative evaluation of the strategies. The findings of the simulation study are the basis for the development of a digital twin for the operational control of multi-zone picking systems. KW - Simulation KW - Kommissionierung KW - Simulation KW - Logistik KW - Planung Y1 - 2022 SN - 978-3-901608-97-1 U6 - https://doi.org/10.11128/arep.20.a2021 VL - 2022 SP - 23 EP - 30 PB - ARGESIM Verlag CY - Wien ER - TY - JOUR A1 - Galka, Stefan A1 - Follath, Alexander A1 - Bross, Florian ED - Bauer, Wilhelm ED - Volk, Wolfram ED - Zäh, Michael T1 - Vorgehensmodell zur Erstellung Digitaler Zwillinge für Produktion und Logistik JF - Zeitschrift für wirtschaftlichen Fabrikbetrieb N2 - Der Digitale Zwilling (DZ) ist ein wichtiger Bestandteil der Industrie 4.0 und ermöglicht Anwendungen wie Predictive Maintenance, virtuelles Prototyping oder die Steuerung von Produktions- und Logistikprozessen. Herausforderungen bei der Entwicklung des Digitalen Zwillings entstehen durch fehlende Struktur und Standards. Mit diesem Beitrag soll ein Vorgehensmodell für die Erstellung eines Digitalen Zwillings im Bereich der Produktion und Logistik aufgezeigt werden. Das Vorgehensmodell hilft bei der Einordnung, für welche Anwendungsfälle ein Digitaler Zwilling entwickelt werden kann, welche Schritte bei einer Umsetzung erfolgen müssen, und gibt einen Überblick über die Voraussetzungen und Komplexität bei der Entwicklung. Das zentrale Element bildet dabei die zielgerichtete Aufbereitung und Analyse der zugrunde liegenden Daten mittels des in der Industrie etablierten Vorgehensmodell CRISP-DM. KW - Digitale Zwillinge KW - Simulation KW - Logistik KW - Produktion Y1 - 2022 U6 - https://doi.org/10.1515/zwf-2022-1127 VL - 117 IS - 11 SP - 691 EP - 696 PB - De Gruyter CY - Berlin ER - TY - JOUR A1 - Melzner, Maximilian A1 - Engelhardt, Lucas A1 - Simon, Ulrich A1 - Dendorfer, Sebastian T1 - Electromyography-Based Validation of a Musculoskeletal Hand Model JF - Journal of Biomechanical Engineering N2 - Regarding the prevention of injuries and rehabilitation of the human hand, musculoskeletal simulations using an inverse dynamics approach allow for insights of the muscle recruitment and thus acting forces on the hand. Currently, several hand models from various research groups are in use, which are mainly validated by the comparison of numerical and anatomical moment arms. In contrast to this validation and model-building technique by cadaver studies, the aim of this study is to further validate a recently published hand model [1] by analyzing numerically calculated muscle activities in comparison to experimentally measured electromyographical signals of the muscles. Therefore, the electromyographical signals of 10 hand muscles of five test subjects performing seven different hand movements were measured. The kinematics of these tasks were used as input for the hand model, and the numerical muscle activities were computed. To analyze the relationship between simulated and measured activities, the time difference of the muscle on- and off-set points was calculated, which resulted in a mean on- and off-set time difference of 0.58 s between the experimental data and the model. The largest differences were detected for movements that mainly addressed the wrist. One major issue comparing simulated and measured muscle activities of the hand is cross-talk. Nevertheless, the results show that the hand model fits the experiment quite accurately despite some limitations and is a further step toward patient-specific modeling of the upper extremity. KW - Elektromyographie KW - Biomechanik KW - Simulation KW - Electromyography KW - Muscle KW - Musculoskeletal system KW - Signals KW - Simulation Y1 - 2021 U6 - https://doi.org/10.1115/1.4052115 VL - 144 IS - 2 PB - American Society of Mechanical Engineers, ASME ER - TY - JOUR A1 - Melzner, Maximilian A1 - Suess, Franz A1 - Dendorfer, Sebastian T1 - The impact of anatomical uncertainties on the predictions of a musculoskeletal hand model – a sensitivity study JF - Computer Methods in Biomechanics and Biomedical Engineering N2 - Outputs of musculoskeletal models should be considered probabilistic rather than deterministic as they are affected by inaccuracies and estimations associated with the development of the model. One of these uncertainties being critical for modeling arises from the determination of the muscles' line of action and the physiological cross-sectional area. Therefore, the aim of this study was to evaluate the outcome sensitivity of model predictions from a musculoskeletal hand model in comparison to the uncertainty of these input parameters. For this purpose, the kinematics and muscle activities of different hand movements (abduction of the fingers, abduction of the thumb, and flexion of the thumb) were recorded. One thousand simulations were calculated for each movement using the Latin hypercube sampling method with a corresponding variation of the muscle origin/insertion points and the cross-sectional area. Comparing the standard hand to simulations incorporating uncertainties of input parameters shows no major deviations in on- and off-set time point of muscle activities. About 60% of simulations are located within a ± 30% interval around the standard model concerning joint reaction forces. The comparison with the variation of the input data leads to the conclusion that the standard hand model is able to provide not over-scattered outcomes and, therefore, can be considered relatively stable. These results are of practical importance to the personalization of a musculoskeletal model with subject-specific bone geometries and hence changed muscle line of action. KW - Biomechanik KW - Simulation Y1 - 2021 U6 - https://doi.org/10.1080/10255842.2021.1940974 SN - 1476-8259 N1 - Corresponding author: Maximilian Melzner VL - 25 IS - 2 SP - 156 EP - 164 PB - Taylor & Francis ER - TY - JOUR A1 - Kramer, Sharlotte L. B. A1 - Jones, Amanda A1 - Mostafa, Ahmed A1 - Ravaji, Babak A1 - Tancogne-Dejean, Thomas A1 - Roth, Christian C. A1 - Nonn, Aida T1 - The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal JF - International Journal of Fracture N2 - The Sandia Fracture Challenges provide a forum for the mechanics community to assess its ability to predict ductile fracture through a blind, round-robin format where mechanicians are challenged to predict the deformation and failure of an arbitrary geometry given experimental calibration data. The Third Challenge (SFC3) required participants to predict fracture in an additively manufactured (AM) 316L stainless steel bar containing through holes and internal cavities that could not have been conventionally machined. The volunteer participants were provided extensive data including tension and notched tensions tests of 316L specimens built on the same build-plate as the Challenge geometry, micro-CT scans of the Challenge specimens and geometric measurements of the feature based on the scans, electron backscatter diffraction (EBSD) information on grain texture, and post-test fractography of the calibration specimens. Surprisingly, the global behavior of the SFC3 geometry specimens had modest variability despite being made of AM metal, with all of the SFC3 geometry specimens failing under the same failure mode. This is attributed to the large stress concentrations from the holes overwhelming the stochastic local influence of the AM voids and surface roughness. The teams were asked to predict a number of quantities of interest in the response based on global and local measures that were compared to experimental data, based partly on Digital Image Correlation (DIC) measurements of surface displacements and strains, including predictions of variability in the resulting fracture response, as the basis for assessment of the predictive capabilities of the modeling and simulation strategies. Twenty-one teams submitted predictions obtained from a variety of methods: the finite element method (FEM) or the mesh-free, peridynamic method; solvers with explicit time integration, implicit time integration, or quasi-statics; fracture methods including element deletion, peridynamics with bond damage, XFEM, damage (stiffness degradation), and adaptive remeshing. These predictions utilized many different material models: plasticity models including J2 plasticity or Hill yield with isotropic hardening, mixed Swift-Voce hardening, kinematic hardening, or custom hardening curves; fracture criteria including GTN model, Hosford-Coulomb, triaxiality-dependent strain, critical fracture energy, damage-based model, critical void volume fraction, and Johnson-Cook model; and damage evolution models including damage accumulation and evolution, crack band model, fracture energy, displacement value threshold, incremental stress triaxiality, Cocks-Ashby void growth, and void nucleation, growth, and coalescence. Teams used various combinations of calibration data from tensile specimens, the notched tensile specimens, and literature data. A detailed comparison of results based of these different methods is presented in this paper to suggest a set of best practices for modeling ductile fracture in situations like the SFC3 AM-material problem. All blind predictions identified the nominal crack path and initiation location correctly. The SFC3 participants generally fared better in their global predictions of deformation and failure than the participants in the previous Challenges, suggesting the relative maturity of the models used and adoption of best practices from previous Challenges. This paper provides detailed analyses of the results, including discussion of the utility of the provided data, challenges of the experimental-numerical comparison, defects in the AM material, and human factors. KW - Fracture KW - Rupture KW - Tearing KW - Deformation KW - Plasticity KW - Metal KW - Alloy KW - Additive manufacturing KW - Simulation KW - Prediction KW - Modeling Y1 - 2019 U6 - https://doi.org/10.1007/s10704-019-00361-1 VL - 218 SP - 5 EP - 61 PB - Springer Nature ER - TY - JOUR A1 - Keim, Vincent A1 - Paredes, Marcelo A1 - Nonn, Aida A1 - Münstermann, Sebastian T1 - FSI-simulation of ductile fracture propagation and arrest in pipelines BT - Comparison with existing data of full-scale burst tests JF - International Journal of Pressure Vessels and Piping N2 - The fracture propagation and arrest control for pipelines transporting rich natural gases and high vapor pressure liquids is based on the Battelle Two-Curve Model (BTCM). Distinct limitations of this model were demonstrated for past and modern steels and gas mixtures. These can be related to the insufficient description of individual physical processes and interactions between the pipe material and transported mixture during the running ductile fracture. In the past, fluid-structure interaction (FSI) models enabled a more sophisticated, coupled analysis of the failure scenario. To quantify their capability of describing the multi-physical processes, the FSI models need to be verified by experimental data from full-scale burst tests (FSBT). Therefore, this paper deals with the simulation of five FSBTs from the literature on API grade X65 pipes with different pipe geometries, mixtures and initial conditions. The FSI is modeled by the coupled Euler-Lagrange (CEL) method. The modified Mohr-Coulomb (MMC) model is implemented in the CEL framework to describe the deformation and ductile fracture in the X65/L450 pipes. 3D Euler equations are used to calculate the mixture decompression with the GERG-2008 equation of state defining the volumetric behavior of a CO2-rich mixture, CH4 and H2. The extended model considers the effect of soil backfill on the pipe deformation and inertia. The numerical predictions agree well with the experimental findings in terms of the crack propagation speed and arrest length underlining the capability of the developed numerical tool. KW - Running ductile fracture KW - Crack arrest KW - Fluid-structure interaction KW - MMC model KW - CO2 decompression KW - Bruchmechanik KW - Fluid-Struktur-Wechselwirkung KW - Pipeline KW - Simulation Y1 - 2020 U6 - https://doi.org/10.1016/j.ijpvp.2020.104067 VL - 182 IS - May PB - Elsevier ER - TY - CHAP A1 - Käsbauer, Johannes A1 - Schmailzl, Anton A1 - Prehm, Jens A1 - Loose, Tobias A1 - Hierl, Stefan T1 - Simulation of Quasi-Simultaneous Laser Transmission Welding of Plastics BT - Optimization of Material Parameters in Broad Temperature Range T2 - Procedia CIRP N2 - Thermo-mechanical simulation offers great opportunities to optimize welding processes of plastics. For realistic simulation, the temperature dependent mechanical properties need to be implemented from ambient temperature to temperatures above the flow temperature. Standard test methods are insufficient for characterization in the entire temperature range because close to the flow temperature the material is too soft for tensile tests and too stiff for rheometry. Therefore, an optimization strategy is developed, that determines unknown material parameters by testing in welding simulations. The unknown parameters are iteratively adjusted to minimize the mismatch between computed and measured set-paths. Thus, important process characteristics are calculated realistically, enabling the computer aided assessment of the weld quality. KW - plastics welding KW - simulation KW - material modelling KW - optimization KW - parameterization KW - Kunststoffschweißen KW - Thermomechanische Eigenschaft KW - Simulation Y1 - 2020 U6 - https://doi.org/10.1016/j.procir.2020.09.136 VL - 94 SP - 737 EP - 741 PB - Elsevier ER -