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- Fakultät Maschinenbau (71)
- Regensburg Center of Biomedical Engineering - RCBE (17)
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Begutachtungsstatus
- peer-reviewed (16)
This paper addresses the problem of properly placing a given task in the manipulator workspace by a heuristic and numeric approach. Thus, the task is placed relatively to the manipulator for each element of the discretized workspace and the required joint torques are determined. The results are are by a torque-based optimization criterion. The modularity of this approach ensures general applicability on various systems and tasks while the high computational effort is treated by GPU parallelization. The method is presented for a given 6DOF manipulator and a highly dynamic trajectory. The resulting interactive map of the manipulator workspace gives an overview of the task dependent dynamic performance, detailed evaluation of certain solutions will show the dexterity of the proposed approach.
EMDLAB: A toolbox for analysis of single-trial EEG dynamics using empirical mode decomposition
(2015)
Background:
Empirical mode decomposition (EMD) is an empirical data decomposition technique. Recently there is growing interest in applying EMD in the biomedical field.
New method:
EMDLAB is an extensible plug-in for the EEGLAB toolbox, which is an open software environment for electrophysiological data analysis.
Results:
EMDLAB can be used to perform, easily and effectively, four common types of EMD: plain EMD, ensemble EMD (EEMD), weighted sliding EMD (wSEMD) and multivariate EMD (MEMD) on EEG data. In addition, EMDLAB is a user-friendly toolbox and closely implemented in the EEGLAB toolbox.
Comparison with existing methods:
EMDLAB gains an advantage over other open-source toolboxes by exploiting the advantageous visualization capabilities of EEGLAB for extracted intrinsic mode functions (IMFs) and Event-Related Modes (ERMs) of the signal.
Conclusions:
EMDLAB is a reliable, efficient, and automated solution for extracting and visualizing the extracted IMFs and ERMs by EMD algorithms in EEG study.
Manual tasks in industrial production are often monotonous, leading to a decrease in concentration and motivation of the worker and thus to deficiencies in the products. With quality as well as performance requirements getting more and more stringent, workers need additional support by their work environment. We developed a novel approach providing worker assistance and inline quality assurance for manual workplaces. The prototypical system Smart Workbench (SWoB) uses a multimodal sensor interface consisting of a 3D depth sensor in combination with a 2D camera to control quality aspects of the product and track the work progress. The bidirectional flow of information is handled via an image processing driven gestural interface and the displaying of advice directly on the work surface. In this paper the developed system is introduced and the current state of evaluating its industrial usage with a manual quality control and packaging task reported.
Early meta-level: deeper understanding of connectivity-states and consequences for state definition
(2015)
In-plant milk-run systems are transportation systems, where materials are delivered from a central storage area to several points of use on defined routes and in short intervals. Milk-run systems generally enable frequent deliveries in smaller lot sizes with short lead times and low inventory at the points of use. In real milk-run systems, the number of deliveries per interval varies due to, e.g., variations in the production program. To enable efficient and stable milk-run system operations, these systems therefore must be able to cope with peaks in the number of deliveries. We develop different strategies for handling these delivery peaks and evaluate them with respect to delivery cost, lead time and service level using real material consumption data from two large companies from the automotive industry.
In this report, the delivery of polyamide 12 (PA 12) powder and powder layer preparation by vibrating steel nozzles is investigated and discussed with respect to its application for laser beam melting. Therefore, a setup was realized which includes a steel nozzle attached to a piezo actor as well as a positioning system. In order t o investigate the mass flow characteristics in dependency on the applied vibration state, a weighing cell is used enabling time-resolved mass flow measurements. Moreover, single-layer patterns consisting of colored and uncolored polyamide 12 were created and characterized regarding surface homogeneity and selectivity before as well as after the melting of the powder layers by a hot plate.
By Laser Beam Melting of polymers (LBM), parts with almost any geometry can be built directly out of CAD files without the need for additional tools. Thus, prototypes or parts in small series production can be generated within short times. Up to now, no multi-material parts have been built by LBM, which is a major limitation of the technology. To realize multi-material parts, new mechanisms for depositing different polymer powders as well as a new irradiation strategy are needed, by which polymers with different melting temperatures can be warmed to their specific preheating temperatures and be molten simultaneously. This is achieved by simultaneous laser beam melting (SLBM). In the process, two different materials are deposited next to each other and preheated a few degrees below their melting temperatures by infrared emitters and laser radiation (λ = 10.60 µm), before in the last step the two preheated powders are molten simultaneously by an additional laser (λ = 1.94 µm). So far, multi-material tensile bars have been realized and analyzed regarding their boundary zone between both materials. The experiments showed that the temperature gradients in the boundary zone and along the building direction seem to be of great importance for the process stability and the resulting part properties. Therefore, a detailed analysis of the occurring temperature gradients during the process is needed to identify adequate process adjustments regarding the temperature controlling. To analyze the temperature gradients, thermocouples positioned inside the powder bed are used. By varying the temperature of the building platform, the influence of different temperature gradients on the resulting part properties is shown.
Im Rahmen dieses Beitrags wird das Schmelzeemulgieren als Verfahren zur Herstel-lung von Polymermikropartikeln vorgestellt. In diesem Prozess wird zunächst ein Polymergranulat in einer kontinuierlichen Phase in Gegenwart geeigneter Additive in einem Rührbehälter aufgeschmolzen, die Rohemulsion in einer Rotor-Stator-Einheit feinemulgiert und anschließend zu einer Suspension abgekühlt. Der Einfluss von Prozessparametern und Systemzusam-mensetzung auf das Emulgierergebnis wird diskutiert und die Anwendbarkeit des Verfahrens für polymere Mikropartikeln anhand von Polypropylen (PP) und Polyethylen (PE-HD) dargestellt. Die erhaltenen Suspensionen werden zur Überführung in Pulverform sprühgetrocknet und die Fließeigenschaften des Pulvers analysiert. Durch trockenes Beschichten mit pyrogener Kieselsäure kann die Fließfähigkeit der erhaltenen Partikeln weiter verbessert werden. Das Verfahren bietet somit einen neuen Zugang zur Herstellung neuer Ausgangsmaterialien für die Additive Fertigung.
By simultaneous laser beam melting (SLBM), parts consisting of different polymer powders can be additively manufactured within one building process. Besides the advantages of conventional LBM, e.g., not needing additional tools and being able to realize parts with almost any geometry, different product requirements can be achieved within a single part. Product requirements may be different chemical resistances or haptic material properties. Therefore, SLBM enlarges the application field for additive manufacturing in general. In the process, two different materials are deposited on the building platform and preheated a few degrees below the melting temperature of the lower melting polymer by infrared emitters. Afterward, a CO2 laser (λ = 10.6 μm) provides the energy for the temperature difference between the preheating temperatures of both materials. Finally, a digital light processing chip is used to achieve simultaneous and flexible energy deposition for melting both preheated polymers. By illuminating the chip with a laser, parts of the beam can be flexibly guided onto the powder bed or into a beam trap. As laser, a single mode thulium laser (λ = 1.94 μm) is used. After melting the layer, a new layer is deposited and the process starts anew. In this paper, polypropylene and polyamide 12 are used as materials. After analyzing the material and melting behavior during the process by a high-resolution thermal imaging system, the parts are qualified regarding their material compatibility at the boundary zone and porosity by cross sections.
In this paper, first results regarding the realization of multi-material parts by Simultaneous Laser Beam Melting (SLBM) of polymers are presented. This new approach allows the layerwise generation of parts consisting of different polymer materials within one building process. Besides the typical advantages of additive manufacturing technologies, such parts can fulfill different product requirements concomitant and therefore could enlarge the overall field of application. The powder materials used for this paper are polyethylene (PE) and a polyamide based thermoplastic elastomer (TPE). After depositing the powder materials next to each other, infrared-emitters heat the lower melting polymer and a CO2 laser provides the preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser melts the two preheated powders simultaneously. The realized specimens are characterized by cross sections and their tensile strengths are determined. Additionally, the new approach of the simultaneous energy irradiation is investigated using a Finite Element Analysis in order to gain a more profound process understanding. In that sense, the influence of the size of the exposure area on the reachable maximum temperatures inside that area was analyzed by the simulation and compared to experimental studies.
In this paper, first results regarding the realization of multi-material parts by Simultaneous Laser Beam Melting (SLBM) of polymers are presented. This new approach allows the layerwise generation of parts consisting of different polymer materials within one building process. Besides the typical advantages of additive manufacturing technologies, such parts can fulfill different product requirements concomitant and therefore could enlarge the overall field of application. The powder materials used for this paper are polyethylene (PE) and a polyamide based thermoplastic elastomer (TPE). After depositing the powder materials next to each other, infrared-emitters heat the lower melting polymer and a CO2 laser provides the preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser melts the two preheated powders simultaneously.The realized specimens are characterized by cross sections and their tensile strengths are determined. Additionally, the new approach of the simultaneous energy irradiation is investigated using a Finite Element Analysis in order to gain a more profound process understanding. In that sense, the influence of the size of the
exposure area on the reachable maximum temperatures inside that area was analyzed by the simulation and compared to experimental studies.
Purpose – The purpose of this paper is to demonstrate the processability of cohesive PE-HD particles in laser beam melting processes (LBM) of polymers. Furthermore, we present a characterization method for polymer particles, which can predict the quality of the powder deposition via LBM processes. Design/methodology/approach – This study focuses on the application of dry particle coating processes to increase flowability and bulk density of PE-HD particles. Both has been measured and afterwards validated via powder deposition of PE-HD particles in a LBM machine. Findings – For efficient coating in a dry particle coating process, the PE-HD particles and the attached nanoparticles need to show similar surface chemistry, i.e. both need to behave either hydrophobic or hydrophilic. It is demonstrated that dry particle coating is appropriate to enhance flowability and bulk density of PE-HD particles and hence considerably improves LBM processes and the resulting product quality. Originality/value – At present, in LBM processes mainly polyamide (PA), 12 particles are used, which are so far quite expensive in comparison to, for example, PE-HD particles. This work provides a unique and versatile method for nanoparticulate surface modification which may be applied to a wide variety of materials. After the coating, the particles are applicable for the LBM process. Our results provide a correlation between flowability and bulk density and the resulting product quality.
In diesem Beitrag wird eine Theorie zur taktorientierten Fertigungssteuerung entwickelt. Es wird der kleinste Repräsentant einer taktorientiert gesteuerten Werkstatt ermittelt - das Ein-Ressourcen- Modell. Durch die Modifikation des Trichtermodells kann ein allgemeingültiges Beschreibungsmodell des Produktionsprozesses bei taktorientierter Fertigungssteuerung erarbeitet werden - das taktorientierte Trichtermodell. Es ermöglicht die Darstellung der Arbeitsbestände im aktuellen Bearbeitungstakt und der des nachfolgenden Taktes. Weiter wird das taktbasierte Trichtermodell in ein taktbasiertes Durchlaufdiagramm überführt. Hiermit kann das Bestandsverhalten des Ein-Ressourcen-Modells über der Zeit dargestellt werden. Das optimale Bestandsverhalten pro Takt kann durch ein idealisiertes Durchlaufdiagramm beschrieben werden. Bei realer Auslastung der Ressource entstehen schwankende Arbeitsbestände pro Takt. Hierbei werden durch zu geringe Bestände pro Takt Auslastungsverluste an der Ressource erzeugt. Durch zu hohe Bestände pro Takt entstehen ohne Kapazitätsanpassungen Verspätungen.
Machine allocation planning in job-shop production is challenging due to the high variability of machining times. The tact-time based production control reduces planning effort also the flow of orders in the shop floor is more predictable. This article takes a deeper look at a single production unit controlled tact based. By enhancing the funnel model and looking at the stock behaviour of production units, a deeper understanding of tact-time based production control is gained.
Die Regensburg Robotics Research Unit entwickelt Regelungsarchitekturen für Telerobotiksysteme für den industriellen Einsatz. Der Beitrag beschreibt das lokale und globale Regelungsmodell hinsichtlich Stabilität und Transparenz auf der Basis der von Lawrence und Yokokohji vorgestellten Regelungsarchitektur und zeigt Simulationsergebnisse auf. Die Modellbildung des geregelten Manipulators, die Kopplung des Operators und des Teleoperators und sowie die Übertragungsfunktion werden dargestellt. Die Simulation des vorgestellten Algorithmus in Matlab/Simulink wird durchgeführt. Innerhalb der Simulationsumgebung ist als Regelstrecke unter der Annahme einer idealen, lokalen Regelung eine im Raum bewegliche Punktmasse modelliert. Die vorgestellte Regelungsarchitektur liefert innerhalb der durchgeführten Simulation vor allem im niederfrequenten Bereich sehr gute Ergebnisse. Die nächsten Schritte sind die experimentelle Evaluierung der lokalen Architektur und der globalen Vierkanalarchitektur an den Robotern.
Der Beitrag beschreibt den Systemaufbau für die Risikobeurteilung zur Realisierung einer sicheren Mensch-Maschine-Kollaboration und stellt die vorgeschriebene Risikobeurteilung gemäß DIN EN ISO 10218-1:2012-01 in folgende Schritten vor: Beurteilung der Erfahrenswerte und des Nutzerverhaltens, Festlegung der Grenzen des Roboters, Identifikation der Gefährdungen und Risikoeinschätzung in den dimensionen Ausmaß, Exposition, Eintrittswahrscheinlichkeit und Vermeidungsmöglichkeit. Die Umsetzung in eine Steuerung, die Steuerungsarchitektur und die eingesetzten Komponenten zur Realisierung einer sicheren Abstandsüberwachung werden beschrieben und in Blockschaltbildern grafisch dargestellt. Die Validität der Sicherheitsfunktion wird diskutiert.
The Impact of the ObamaCare Excise Tax on Innovation and Entrepreneurship – Early Empirical Findings
(2015)
This study addresses aspects of governmental influence on innovation by analyzing the impact of the ObamaCare excise tax on the medical device industry. We initially give an overview of common approaches to measuring innovativeness and entrepreneurship, empirically assess whether existing metrics are suitable for investigating the innovation performance of the U.S. medical device industry, and define a new measure (firm innovation activity) for entrepreneurship. Then we perform a quantitative analysis to explore the impact of the tax. We analyze more than 60,000 product clearances from 1996 to 2013, using the FDA database. We find a significant relationship between product counts and revenues for one segment. Contrary to the present criticism of the excise tax, we find hardly any noteworthy response in either firm innovation activity or number of products launched in the year after the tax was introduced. The 2013 reduction of new product submissions is well within the limits of typical annual fluctuations observed in previous years. This provides a first indication that the excise tax act did not have a strong impact on innovative activities through the present.
Innovation diffusion points toward how innovations spread into the market after launch. This paper investigates diffusion dynamics at market entry time and proposes a new evolution pattern at the intersection between inventions and innovations. With this in mind, we initially prove that patent filings correlate with new product introductions in the U.S. spine market. Then we test our new theory supposing that certain patent filing threshold numbers accelerate strong economic returns in terms of innovations. We find that firms hitting certain patent filing thresholds significantly increase their product launches in the mentioned market. Moreover, the results seem to indicate that economic returns of inventions may be measured substantially. Thus, this paper suggests a new research area by utilizing our proposed concept about an Innovation Outcome Trigger Value (IOTV). Furthermore, the implications may also be interesting for practitioners, since we empirically prove that inventive activities turn out to be worthwhile, indeed.
This book proposes a radically new approach for characterizing thermophysical and mechanical properties of zeolite-based adsorbent coatings for Adsorptive Heat Transformers (AHT). It presents a developed standard protocol for the complete characterization of advanced coated adsorbers. Providing an in-depth analysis of the different procedures necessary for evaluating the performance of adsorbers, it also presents an analysis of their stability under the hydrothermal and mechanical stresses during their entire life cycle. Adsorptive Heat Transformers (AHT), especially adsorption chillers and heat pumps, are considered to be promising technologies to increase thermal energy efficiency. Nevertheless, an overall increase in performance of this apparatus is necessary for them to be considered a mature technology to be used commercially. Development of innovative coated adsorbers can be perceived as a key issue for the enhancement of AHT technology. This procedure relies on the deposition, either by means of a binder or by direct crystallization, of the adsorbent material over a metallic heat exchanger, aiming at the improvement of the heat transfer between the external heat source and the adsorbent itself. This book offers a valuable resource to those working on the development of novel adsorbent materials and advanced adsorbent beds for heating and cooling applications. It is also intended for researchers interested in renewable energy and energy efficiency.
In this paper, a new method for a minimum-error pose estimation of cylinder axes based on apparent contour line features from multiple views is presented. Novel model equations for both single and particularly multiple views are derived, and based upon these, an algorithm for least squares fitting the model to imaged cylinder contour line features is introduced. The good performance of the proposed algorithm is shown by solving an exemplary fitting problem.
Lines are one of the basic features that are used to characterise the content of an image and to detect objects. Unlike edges or segmented blobs, lines are not only an accumulation of certain feature pixels but can also be described in an easy and exact mathematical way. Besides a lot of different detection methods, the Hough transform has gained much attention in recent years. With increasing processing power and continuous development, computer vision algorithms get more powerful with respect to speed, robustness and accuracy. But there still arise problems when searching for the best parameters for an algorithm or when characterising and evaluating the results of feature detection tasks. It is often difficult to estimate the accuracy of an algorithm and the influences of the parameter selection. Highly interdependent parameters and preprocessing steps continually lead to only hardly comprehensible results. Therefore, instead of pure trial and error and subjective ratings, a systematic assessment with a hard, numerical evaluation criterion is suggested. The paper at hand deals with the latter ones by using a human-generated ground truth to approach the problem. Thereby, the accuracy of the surveyed Kernel-based Hough transform algorithm was improved by a factor of three. These results are used for the tracking of cylindrical markers and to reconstruct their spatial arrangement for a biomedical research application.
For structures made of carbon fiber-reinforced plastics (CFRP), fast, robust, and reliable repair technologies are mandatory for economical usage. In this paper, the authors explain their strategy and experiences. An automated process is proposed to achieve the challenging goals. A general overview on the origin, effects, and analysis of contaminants in CFRP structures and the relationship to the achievable strength of adhesive bonds are given. For the repair of composite structures using adhesive bonding, surface pretreatment is a key factor in terms of reliability and strength. Different surface treatment processes such as grinding, grit blasting, plasma and pulsed lasers treatments are discussed. Furthermore, the possibilities and technical implementation of an automated milling process for the repair of composite structures are presented. This change from manual production to automation tremendously improved the quality and duration of the repair and allows the creation of a uniform surface for adhesive bonding. Further integration of novel technologies is discussed and will further support and enhance the repair in the near future.
Least squares pose estimation of cylinder axes from multiple views using contour line features
(2015)
In this paper, a new method for a minimum-error pose estimation of cylinder axes based on apparent contour line features from multiple views is presented. Novel model equations for both single and particularly multiple views are derived, and based upon these, an iterative algorithm for least squares fitting the model to imaged cylinder contour line features is introduced. The good performance and fast convergence of the proposed algorithm is shown by solving exemplary fitting problems.
Modeling, identification and control of an antagonistically actuated joint for telerobotic systems
(2015)
Within this paper a modeling, identification and control technique for an antagonistically actuated joint consisting of two pneumatically actuated muscles is presented. The antagonistically actuated joint acts as a test bench for control architectures which are going to be used to control an exoskeleton within a telerobotic system. A static and dynamic model of the muscle and the joint is derived and the parameters of the models are identified using a least-squares algorithm. The control architecture, consisting of a inner pressure and an outer position controller is presented. The pressure controller is evaluated using switching valves compared against proportional valves.
Kontinuierliche Bemühungen zur Vermeidung präanalytischer Fehler und zur Optimierung der zeitlichen Abläufe bei der Blutgasanalyse (BGA) sind wichtig.
In einer prospektiven Beobachtungsstudie wurde untersucht, ob durch Einführung neuer, mit einem Strichcode versehener Probennehmer und von Analysatoren mit automatisierter Verarbeitung der Proben, verglichen mit dem bisherigen Vorgehen, Vorteile resultieren.
In einer jeweils 4-wöchigen Testphase wurde für das herkömmliche BGA-System (Kontrollgruppe) und unter Verwendung der neuen, mit einem Strichcode versehenen Probennehmer und automatischer Prozessierung der Blutproben (Testgruppe) die Zeitdauer bis zum Vorliegen der Ergebnisse bei Durchführung einer BGA gemessen. Zudem wurde die Häufigkeit präanalytischer Fehler quantifiziert. Schließlich wurde untersucht, ob eine Liegedauer der Probennehmer von 10 min vor Vermessung der Probe Auswirkungen auf die resultierenden Ergebnisse des Sauerstoff- (pO2) und des Kohlendioxidpartialdrucks (pCO2) hat.
In der Kontrollgruppe zeigten sich häufig präanalytische Fehler (Vernachlässigen des Entlüftens der Probennehmer und der Homogenisierung mithilfe des manuellen Schwenkens vor Beginn des Messvorgangs). Bei Analyse von BGA-Proben mit einer zeitlichen Latenz von 10 min nach Abnahme wurden in der Kontrollgruppe signifikant erhöhte pO2-Werte [Mittelwert (MW) 118,4 mmHg bei Messung unmittelbar nach Abnahme, MW 148,6 mmHg bei Messung mit 10-min-Latenz] und signifikant erniedrigte pCO2-Werte (40,5 vs. 38,3 mmHg) gemessen. In der Testgruppe zeigten sich signifikant erhöhte pO2-Werte (115,3 vs. 123,7 mmHg); die pCO2-Werte waren hier unverändert. Ein Zeitgewinn bis zum Vorliegen der Messergebnisse ließ sich in der Testgruppe nicht feststellen.
Die Umstellung auf mit einem Strichcode versehene Probennehmer und automatisierte Verarbeitung der Blutproben am Analysator war im klinischen Alltag problemlos möglich. Ein Zeitgewinn bei der BGA resultierte nicht. Allerdings waren Vorteile im Hinblick auf die Reduzierung präanalytischer Fehler erkennbar. Eine verzögerte Analyse von Blutproben kann, abhängig vom Typ des Probennehmers, zu signifikanten und klinisch relevanten Veränderung der Messwerte von pO2 und pCO2 führen.
Point of care testing with blood gas analysis (BGA) is an important factor for intensive care medicine. Continuous efforts to optimize workflow, improve safety for the staff and avoid preanalytical mistakes are important and should reflect quality management standards.
In a prospective observational study it was investigated whether the implementation of a new system for BGA using labeled syringes and automated processing of the specimens leads to improvements compared to the previously used procedure.
In a 4-week test period the time until receiving the final results of the BGA with the standard method used in the clinical routine (control group) was compared to the results in a second 4-week test period using the new labeled syringes and automated processing of the specimens (intervention group). In addition, preanalytical mistakes with both systems were checked during routine daily use. Finally, it was investigated whether a delay of 10 min between taking and analyzing the blood samples alters the results of the BGA.
Preanalytical errors were frequently observed in the control group where non-deaerated samples were recorded in 87.3 % but in the intervention group almost all samples (98.9 %) were correctly deaerated. Insufficient homogenization due to omission of manual pivoting was seen in 83.2 % in the control group and in 89.9 % in the intervention group; however, in the intervention group the samples were homogenized automatically during the further analytical process. Although a survey among the staff revealed a high acceptance of the new system and a subjective improvement of workflow, a measurable gain in time after conversion to the new procedure could not be seen. The mean time needed for a complete analysis process until receiving the final results was 244 s in the intervention group and 201 s in the control group. A 10-min delay between taking and analyzing the blood samples led to a significant and clinically relevant elevation of the values for partial pressure of oxygen (pO(2)) in both groups compared to the results when analyzing the samples immediately (118.4 vs. 148.6 mmHg in the control group and 115.3 vs. 123.7 mmHg in the intervention group). When using standard syringes the partial pressure of carbon dioxide (pCO(2)) was significantly lower (40.5 vs. 38.3 mmHg) whereas no alterations were seen when using the labeled syringes.
The implementation of a new BGA system with labeled syringes and automated processing of the specimens was possible without any difficulties under daily clinical routine conditions in this 10-bed intensive care unit (ICU). A gain of time could not be measured but a reduction in preanalytical errors using the labeled syringes with automated processing was found. Delayed analysis of blood samples can lead to significant changes in pO(2) and pCO(2) depending on the type of syringe used.
The numerical simulation of penetration into sand is one of the most challenging problems in computational geomechanics. The paper presents an arbitrary Lagrangian-Eulerian (ALE) finite element method for plane and axisymmetric quasi-static penetration into sand which overcomes the problems associated with the classical approaches. An operator-split is applied which breaks up solution of the governing equations over a time step into a Lagrangian step, a mesh motion step, and a transport step. A unique feature of the ALE method is an advanced hypoplastic rate constitutive equation to realistically predict stress and density changes within the material even at large deformations. In addition, an efficient optimization-based algorithm has been implemented to smooth out the non-convexly distorted mesh regions that occur below a penetrator. Applications to shallow penetration and pile penetration are given which make use of the developments.
In deep-drawing dies for steel sheet parts of car bodies huge masses are moved. To prevent vibrations, which occur by sudden acceleration or stopping of those masses, elastomeric tubular dampers [1] are used. The dampers are made out of carbon filled elastomers. A good knowledge about the material behaviour of metals is available. But for the numerical investigation of complete deep-drawing dies the elastomeric dampers must be taken into account, too. To characterize the material behaviour of the elastomers tensile tests and pressure tests were carried out. The received material data from the tests were read into LS-DYNA [2]. Simulation models of the tensile test and the pressure test were created for LS-DYNA according to the real dimensions and boundary conditions. For validation purposes, calculations of loading cycles were done to enable a comparison between test data and simulation results. For the calculations the implemented material model *MAT_SIMPLIFIED_RUBBER_WITH_DAMAGE (*MAT_183) was used. The comparison shows a good fitting between the test data and the calculation results with respect to the mechanical material behaviour by using this material model in single loading cases. The settings from the simulations of material tests were transferred to simulations of dampers, which are used in deep-drawing dies.
In order to achieve the energy and efficiency goals in modern automotive press shops, press systems with increasingly high stroke rates are being implemented (Meinhardt in proceedings of ACI forming in car body engineering. Bad Nauheim, Germany 2012). As a side effect, the structural dynamic loads on the press and especially on the forming tool increase. Hence, to design reliable and withstanding forming tools, a detailed knowledge of the vibrations and resulting critical loads is essential. In this paper, the main focus is put on the vibration of the blankholder—the heaviest moving component in the forming tool. To predict those vibrations, a coupled multibody-finite element simulation (MBS-FEM) is conducted, which combines rigid and elastic modeling approaches. Also, an experimental validation of the blankholder vibration under operational load is carried out. To compare the numerical and experimental results—both in time and frequency domain—an 1/3-octave analysis of a blankholder’s vibrational speed is performed. The test measurements agree well with the MBS-FEM simulation.
Finite element simulation of blankholder’s lift-off in a deep drawing tool using Abaqus/Standard
(2015)
In the deep drawing tools for forming car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the deep drawing tool and on the press. Therefore a detailed knowledge about the blankholder’s lift-off event is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of a blankholder’s lift-off in a selected automotive deep drawing tool is presented enabling identification of regions of critical stresses. The FEM model is built within the Abaqus/CAE environment and solved with Abaqus/Standard. Each dynamic analysis is preceded by a static analysis where the gravity load is applied and the lifting bolts are pre-stressed. A special emphasis is put on modeling the elastomer dampers, which are installed between lifting bolts and the blankholder to avoid hard impacts during the lift-off event. Those dampers are modelled using a hyperelastic material with hysteresis. In addition, an experimental validation of a blankholder’s vibration under operating loading was carried out. The simulation results are in good agreement with the measurements.
A Graphical User Interface for Simulating Resin-Transfer-Molding Combining LS-DYNA and OpenFOAM
(2015)
The paper describes parts of the joint research project Swim-RTM including several industrial and academic partners. Its goal is to combine LS-DYNA and the open-source CFD solver OpenFOAM to simulate the production process of continuous fiber-reinforced plastics, particularly the resin-transfer-molding (RTM) process, in which the layers of dry fabric (unidirectional or woven) are formed in the mold (draping) and then filled with liquid resin with high pressure at injection points. Through a combined analysis of both the structural mechanical and the fluid dynamical phases, a better prediction and thereby optimization of the textile components properties as well as injection points can be achieved, improving the manufacturing process. The draping simulation of the fabric layers is carried out with LS-DYNA, while the injection simulation of the matrix material is performed in full 3D with OpenFOAM. A key question in this research project is how local porosities can be derived from the structural computation in the draping step. The purpose of the presented subproject is to develop a graphical user interface (GUI) to enable the simulation of the entire RTM process of long-fiber-reinforced components including the transfer of results between the draping and injection phases. The complete simulation task is relatively complex and involves several software packages, meaning a high effort for the user to get familiarized with. To circumvent this, the GUI aims at requiring from the user only the minimum necessary input data, creating and running the simulation and mapping tasks in the background, and showing graphically all demanded intermediate and final results. For the draping step several current fabric materials such as *MAT_034, *MAT_234, *MAT_235, *MAT_249 are available. Several modelling techniques for the composite setup are also conceivable, including a workflow similar to metal forming applications. In the injection step the fabric is modelled as a porous medium and different transport models and liquid resin types are at hand. For the data transfer between the draping and injection models, i.e. the mapping of data between shell and volume meshes within the developed GUI, first the OpenFOAM volume mesh is converted to LS-DYNA format and the necessary passing parameters are extracted from the output files, then the mapping tool DYNAmap [3] from DYNAmore GmbH is invoked, and finally the OpenFOAM command files are created. After the injection simulation is started and successfully terminated, information, such as the distribution of air inclusions or the shear stress distribution to analyze the reorientation of component fibers, is available and can be transferred from the 3D fluid mesh to an LS-DYNA shell mesh for further computations, for instance a crash simulation. This backward data mapping between volume and shell meshes can then be performed inside the GUI.
Purpose:
A prepreg production device in laboratory scale is used to develop the production process of unidirectionally reinforced prepregs.
Design/methodology/approach:
The aim of the prepreg production device is to impregnate different types of reinforcement fibers with an arbitrarily selectable thermoset matrix system that completely satisfies the requirements for autoclave processing. As the prepreg production device is designed and built up modularly every module corresponds one step in the process.
Findings:
To identify the parameters of the production process and investigate its sensitivity on the material quality of both the prepreg as an uncured semi-finished product and the composite as the cured material experimental investigations regarding the resin flow, fiber volume content, mass per unit area and void content are carried out. Overall four material combinations have been investigated, where in each case the selected impregnation temperature and the width of the impregnation gap has been reproducibly varied in selected steps.
Research limitations/implications:
The experimental characterization of the prepregs and of the composite material is carried out according to German standards.
Detecting Defects Reliably
(2015)
The integration of a broadband pyrometer in a 3-D scanner enables a continuous and local temperature measurement during the quasi-simultaneous laser transmission welding process. Welding tests on polyethylene samples show that defects can be clearly identified based on the temperature signal, despite a high scanning velocity.
A pyrometer, integrated into a 3D‐scanner, offers the possibility to measure the weld seam temperature at quasi‐simultaneous laser transmission welding. Experimental studies have shown that gaps located in the joining zone can be identified by a temperature rise even at a high scanning velocity. This enables the implementation of algorithms for observation and control strategies.
Fehlstellen sicher erkennen
(2015)
Rechenzeitoptimierte Temperaturfeldberechnung beim quasisimultanen Laser-Durchstrahlschweißen
(2015)
Beim quasisimultanen Laser-Durchstrahlschweißen von Kunststoffen wird bisher die FEM-Simulation wegen der Vielzahl von Umläufen des Laserstrahls und der damit verbundenen hohen Rechenzeit kaum eingesetzt. Um die Temperaturfeldberechnung zur Prozessauslegung und -optimierung praktikabel nutzen zu können, ist eine Reduktion der Rechenzeit zwingend erforderlich.
Zur Simulation von Schweißvorgängen in ANSYS-CLASSIC werden die
thermischen Lasten mithilfe von Ersatzwärmequellen auf Basis von APDL-Routinen berechnet. Im Gegensatz dazu wird in dieser Arbeit eine analytische Lastfunktion zur Berechnung der thermischen Last für das quasismultane Laser-Durchstrahlschweißen vorgestellt.
Im Vergleich zur Temperaturfeldberechnung mit Ersatzwärmequelle
kann bei der Berechnung eines dreidimensionalen Modells die
Rechenzeit von mehreren Wochen auf wenige Stunden und für ein zweidimensionales auf nur wenige Minuten reduziert werden.
Navigated Femur First Total Hip Arthroplasty leads to improved Biomechanical Outcome after surgery
(2015)
Thoracolumbar spine model with articulated rigcage for the prediction of dynamic spinal loading
(2015)
The musculoskeletal load scenario of computer-assisted Femur-First THR up to one year after surgery
(2015)
The characterization of oxygen diffusion zone in titanium and the effect of this zone on macroscopic properties are still of high interest for a base to predict and to enhance life time of titanium and titanium alloy components. The aim of this study was to contribute to the understanding of the impact of oxygen on fatigue properties of oxygen diffusion hardened Ti and Ti alloys. Oxygen diffusion hardening implies two process steps, first the oxidation of the surface and secondly the diffusion of oxygen into metal matrix. Due to the one-step treatment used in this study the oxidation step could take place easily avoiding scaling and grain boundary diffusion. In spite of this precaution, the fatigue properties in the present study were found to be decreased after the performed oxygen diffusion hardening. The reason for the reduction of mechanical properties were claimed to be oxide clusters on the surface acting as crack initiation sites. Comparison and discussion with literature revealed varying partially contradictory fatigue results. Therefore precise analysis of the fatigue failure is necessary as a base for further development of the oxygen diffusion hardening.
Effect of the fractured calcaneus's peripheral fragment displacement on the triceps surae function
(2015)
We have developed a novel, computer-assisted operation method for minimal-invasive total hip replacement (THR) following the concept of “femur first/combined anteversion,” which incorporates various aspects of performing a functional optimization of the prosthetic stem and cup position (CAS FF). The purpose of this study is to assess whether the hip joint reaction forces and patient’s gait parameters are being improved by CAS FF in relation to conventional THR (CON). We enrolled 60 patients (28 CAS FF/32 CON) and invited them for gait analysis at three time points (preoperatively, postop six months, and postop 12 months). Data retrieved from gait analysis was processed using patient-specific musculoskeletal models. The target parameters were hip reaction force magnitude (hrf), symmetries, and orientation with respect to the cup. Hrf in the CAS FF group were closer to a young healthy normal. Phase-shift symmetry showed an increase in the CAS FF group. Hrf orientation in the CAS FF group was closer to optimum, though no edge or rim-loading occurred in the CON group as well. The CAS FF group showed an improved hrf orientation in an early stage and a trend to an improved long-term outcome.
Different target areas within the concept of combined cup and stem anteversion have been published for total hip arthroplasty (THA). We asked whether component positioning according to eight standard combined anteversion rules is associated with (1) more physiological gait patterns, (2) higher improvement of gait variables and (3) better clinical outcome after THA.In a prospective clinical study, 60 patients received cementless THA through an anterolateral MIS approach in a lateral decubitus position. Six weeks postoperatively, implant position was analysed using 3D-CT by an independent external institute. Preoperatively, six and 12 months postoperatively range of motion, normalized walking speed and hip flexion symmetry index were measured using 3D motion-capture gait analysis. Patient-related outcome measures (HHS, HOOS, EQ-5D) were obtained by an observer blinded to 3D-CT results. Eight combined anteversion definitions and Lewinnek's "safe zone" were evaluated regarding their impact on gait patterns and clinical outcome.Combined cup and stem anteversion according to standard combined anteversion definitions as well as cup placement within Lewinnek's "safe zone" did not influence range of motion, normalized walking speed and/or hip flexion symmetry index six and 12 months after THA. Similarly, increase of gait parameters within the first year after THA was comparable between all eight combined anteversion rules. Clinical outcome measures like HHS, HOOS and EQ-5D did not show any benefit for either of the combined anteversion definitions.Standard combined cup and stem anteversion rules do not improve postoperative outcome as measured by gait analysis and clinical scores within one year after THA.
We report the kinematic and early clinical results of a patient- and observer-blinded randomised controlled trial in which CT scans were used to compare potential impingement-free range of movement (ROM) and acetabular component cover between patients treated with either the navigated 'femur-first' total hip arthroplasty (THA) method (n = 66; male/female 29/37, mean age 62.5 years; 50 to 74) or conventional THA (n = 69; male/female 35/34, mean age 62.9 years; 50 to 75). The Hip Osteoarthritis Outcome Score, the Harris hip score, the Euro-Qol-5D and the Mancuso THA patient expectations score were assessed at six weeks, six months and one year after surgery. A total of 48 of the patients (84%) in the navigated 'femur-first' group and 43 (65%) in the conventional group reached all the desirable potential ROM boundaries without prosthetic impingement for activities of daily living (ADL) in flexion, extension, abduction, adduction and rotation (p = 0.016). Acetabular component cover and surface contact with the host bone were > 87% in both groups. There was a significant difference between the navigated and the conventional groups' Harris hip scores six weeks after surgery (p = 0.010). There were no significant differences with respect to any clinical outcome at six months and one year of follow-up. The navigated 'femur-first' technique improves the potential ROM for ADL without prosthetic impingement, although there was no observed clinical difference between the two treatment groups.
Musculoskeletal simulations of lumbar spine loading rely on a geometrical representation of the anatomy. However, this data has an inherent inaccuracy. This study evaluates the influence of defined geometrical parameters on lumbar spine loading utilising five parametrised musculoskeletal lumbar spine models for four different postures. The influence of the dimensions of vertebral body, disc, posterior parts of the vertebrae as well as the curvature of the lumbar spine was studied. Additionally, simulations with combinations of selected parameters were conducted. Changes in L4/L5 resultant joint force were used as outcome variable. Variations of the vertebral body height, disc height, transverse process width and the curvature of the lumbar spine were the most influential.
These parameters can be easily acquired from X-rays and should be used to morph a musculoskeletal lumbar spine model for subject-specific approaches with respect to bone geometry. Furthermore, the model was very sensitive to uncommon configurations and therefore, it is advised that stiffness properties of discs and ligaments should be individualised.