Advanced Materials Research Vol. 1018

Abstract: On all company levels, control loops are a proper way to control and optimize processes. As energy and resource efficiency come into focus and the increasing wish of the customer for individualized products adds even more complexity to the control task, standard control systems are unable to meet these increased demands. In the field of Self-Optimization, researchers try to enhance these control loops with more degrees of freedom by an adaption of the inner rules and objectives of the controller and the application of cognitive systems. This paper presents some promising developments that have been made in the field of self-optimization and shows which challenges research will have to face, like the missing standardization, the complexity of multi-parameter optimization, the problem of complex and conflicting goal systems and the technical risk management for non-deterministic system behavior.

Abstract: In this article you find the results of the research project "Modelling and design of dynamic business and communication processes in the factory” which is funded by the German Research Foundation (DFG). The main result is a methodology for the identification and improvement of communication in factories, which consists of the three models: descriptive model, evaluation model, procedure model. The descriptive model is based on the method of matrix modelling and enables the depiction of communication structures. The evaluation model is conductive to the assessment of communication circumstances in the factory and the procedure model explains the course of action necessary for the practical use of the descriptive and evaluation model. According to the developed methodology the three models were implemented in an EXCEL-based software-tool which enables the practical use of the methodology. The software-tool provides a possibility to not only describe the communication structure of factories, but also to identify communication processes necessary to run the factory. Moreover it is possible to detect inadequacies of communication circumstances and derive measures to adjust them appropriately. In the following article the methodology and the software-tool are described in detail. For an optimal comprehension of the methodology each of the three models is detailed. In order to obtain an idea of how the software-tool works and how it looks like, its three components are explained.

Abstract: A rising trend to miniaturization and function integration requires new materials, tools, manufacturing setups and quality inspection strategies for mass production of micro mechanical systems (MMS). In most scenarios, quality inspection is carried out manually. An expert takes samples out of the manufacturing process and investigates them by means of tactile or optical measurement systems. This time consuming quality inspection process leads to low inspection rates, especially in bulk manufacturing processes, where manufacturing frequencies of 400 parts per minute are common. This contribution introduces an automated optical quality inspection method based on a digital holographic system, which acquires 2D texture and 3D shape information in one single measurement step. Based on 3D data, an automated point separation algorithm splits the measured object shape into elementary geometries and calculates form and position deviations compared to an object model. In the final step, a 2D surface inspection procedure based on multi-scale texture analysis detects surface defects with respect to the separated elementary geometries and fuses the result from the 3D shape and the 2D texture analysis to a final rejection decision. The capability of the proposed quality inspection method is demonstrated in a micro cold forming scenario, where a micro cup smaller than 1 mm in all geometric dimensions is the object under investigation.

Abstract: As this paper demonstrates, benchmarking is a powerful concept for increasing a company's success. It visualizes the differences in performance through internal or external indicators and is applied in almost all corporate divisions successfully. An important part of the benchmarking process is the selection of indicators that allow for a significant comparison. The requirements linked to the indicators are derived from the objectives of the specific benchmarking project. The use of benchmarking with respect to energy efficiency in product manufacturing promises a transparent presentation of performance differences and the possibility to derive optimization potentials - provided that appropriate energy figures can be found. The future challenge is to develop a system with standardized billing and key energy indicators that enable a cross-comparison of the energy efficiency in the production. This project is described in the research project E|Benchmark, part of the research network Green Factory Bavaria and funded by the Bavarian State Ministry for Science, Education and Arts.

Abstract: Companies in Germany will have to face major challenges caused by current and future social trends. The shortage of labor and the importance of the work-life balance for employees will increase significantly. Thus, companies have to adapt to the demographic development as well as to the change in the personal values of individuals by implementing methods that enhance job satisfaction. This paper will analyze and examine the suitability of Lean Productions Systems for companies in Germany against the background of these future changes. It will be shown that the individual job satisfaction of employees within production systems is the key factor to success in order to meet the social trends. Therefore, a new approach for the design and operation of a people-centered production system will be described.

Abstract: A learning factory is a learning environment that promotes the competent development of people. Highly qualified employees are a basic prerequisite for competitive and future-oriented production. Therefore, companies and universities increasingly tend to develop and operate learning factories. So far, existing learning factories are mainly used to mediate subjects as energy- and lean-management. In addition to these topics, it becomes increasingly important for many companies to sustainably produce now and in the future. However this topic is rarely taught in learning factories. This paper presents a concept of how companies and universities can qualify people in learning factories for the new challenges arising from a sustainable manufacturing strategy. For this, content and methods will be identified which affect the three dimensions of sustainability. Secondly, the feasibility to apply these contents and methods in a learning factory is assessed.

Abstract: This work presents the results of manufacturing three-dimensional tensile test specimens using widespread hardware usually deployed for laser cladding. Using a laser cladding processing head with coaxial powder feed and a 3-axis-CNC-system macroscopic three-dimensional tensile test specimens have been built by means of additive manufacturing process from cobalt-based Stellite 21 powder on a substrate made of S235JR steel. The additive process has been made by generating a CAD-model of the geometry under investigation and translating it into G-Code using VisCAM RP4.0 software from Marcam Engineering usually used for selective laser melting devices. An interface translating G-Code into program code which is executable by a CNC-system has been developed, additionally the CNC-code has been extended in order to trigger the processing laser. The specimens have been generated under consideration of three different exposure strategies with respect to path orientation in order to investigate their influence on mechanical properties of processed material. After the post-processing by milling and deburring the specimen underwent tensile tests, additionally metallographic investigations and hardness measurements have been done in order to investigate the influence of process parameters on porosity, cracks distribution and hardness of Stellite 21. It has been found that there are connections between process parameters and porosity and cracks of generated samples. Compared with cast material the Young’s Modulus has been found to decrease slightly without significant relation with path orientation, while ultimate tensile strength has been found to be higher than that of cast material, with a significant dependency of the orientation of the laser path. Achieved results show the technical possibility of creating three-dimensional samples by the widespread laser cladding process and hardware. Furthermore, static mechanical properties of generated parts prove to be competitive to as-cast parts in terms of elasticity and ultimate tensile strength.

Abstract: For the production of forged components, it is necessary to coordinate and optimize the production stages along the different process chains. This includes the mainstream processes as well as the associated process chains and the respective processes of die manufacturing. Until now, these processes and process chains are commonly planned and optimized independently due to different and often contradictory target criteria. This paper deals with an extended approach to a holistic planning and optimization of forging process chains by means of the optimization technique Genetic Algorithm (GA) in order to reduce production costs and time.

Abstract: The shift to satisfied customer markets forces manufacturers to offer customised products. Moreover, product lifecycles are shortened, which requires a faster development of products and corresponding production systems. Both challenges amplify complexity in production. This complexity is usually confronted with flexibility. A new approach offering decentralised structures, and thereby flexibility, comes from cybertronic systems (CTS), which are further developed mechatronic systems with the capability to communicate through open networks with other such mechatronic systems. Up to now no integrated development process to engineer cybertronic products (CTP) and production systems (CTPS) has been developed, although such a process is essential to use their beneficial properties for today’s market conditions. Therefore, research is conducted in the research project mecPro². First, the properties of cybertronic systems are investigated and dissociated from those of mechatronic systems. Based on these properties, the connections of CTP and CTPS are analysed and a systematics for description for both is identified. With this the model-based development processes of CTP and CTPS can be further defined as well as their intersections and afterwards implemented in a data model. Finally, the development process is summarised in a product lifecycle management software to support the development process.

Abstract: Today’s engineering demands the collaboration of various specialists in order to provide quality excellence and meet time constraints within engineering projects. Even though mechatronic engineering methodologies display handy instruments (e. g. VDI 2206), they are not sufficiently supported by digital engineering tools. Digital engineering tools are rather characterized based on its discipline-specific functions and omit a holistic mechatronic thinking. On this account, the paper introduces a reference model for mechatronic engineering tools. Thereby, the model boundary bases on mechatronic principles and concepts (e. g. the mechatronic principle of interdisciplinary collaboration and the concept of interdisciplinary knowledge provision). The model is structured into three reference perspectives: Process, application and artifact. While the reference perspective process claims the requirements of mechatronic engineering processes, the reference perspective application represents the interaction with mechatronic developers and the reference perspective artifact forms the digital representation of mechatronic production systems. Being designed deductively, industry-based expert interviews and workshops ensure feasibility of the paper’s approach. Finally, the potential for integration in current software maturity models and the company-specific scaling of engineering tools is mentioned as part of the application’s scope.