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Drescher B.,Institute for Machine Tools and Industrial Management | Klein T.P.,Institute for Machine Tools and Industrial Management | Spiegelberger B.,ITQ GmbH | Stetter R.,Institute for Machine Tools and Industrial Management | Reinhart G.,ITQ GmbH
IEEE/ASME International Conference on Advanced Intelligent Mechatronics, AIM | Year: 2014

Despite the description of development projects by engineering models and methods the growing complexity of mechatronic engineering processes has not been sufficiently addressed within the research community. Currently a holistic and integrative mechatronic approach is still missing. The paper describes shortcomings of current macroscopic engineering and maturity models. As a consequence mechatronic engineering methods are outlined and synthesized into a holistic macroscopic engineering model the Mechatronic Reference Model (MRM). The model considers the mechatronic engineering process starting from the requirements engineering up to the final acceptance test of the production system. It outlines a three-layer-concept: The top layer consists of process areas along the mechatronic engineering process. The second layer stripes down and details each process area into several activity groups whilst the third layer deduces planning steps per activity group. Finally the MRM represents the basis for further research activities especially in terms of the integration of agile engineering models used for software development and the evaluation of mechatronic integration in engineering tools. © 2014 IEEE.


Zaeh M.F.,Institute for Machine Tools and Industrial Management | Poehler A.,Institute for Machine Tools and Industrial Management
Production Engineering | Year: 2011

For more than 50 years rotational friction welding has been successfully used for joining metallic materials. Since lightweight structures became established in industry new challenges emerge to rotational friction welding, that have not yet been studied. This report considers vibrations in rotational friction welding in order to identify possibilities and means and to avoid damage of the component structure by the production process. First the solutions available in the patent literature with the main scope on the reduction of the load are discussed. The literature does not address the source of the vibrations. Therefore, in a further step, the measured oscillations are investigated in experiments. There the focus is the origin of the oscillations building up within the workpiece. Diagrams show in which sections of the process the vibrations have to be expected. In addition to the investigation regarding the origin an analytical method enables the calculation of the oscillations. Finally, novel possibilities to reduce the vibrations, based on the results are introduced. © 2010 German Academic Society for Production Engineering (WGP).


Michniewicz J.,Institute for Machine Tools and Industrial Management | Reinhart G.,Institute for Machine Tools and Industrial Management
Mechatronics | Year: 2015

This paper presents an approach, which allows the utilization of the entire flexibility of modular robot cells. Solution independent requirements of products to be assembled are automatically extracted from their individual CAD files and used for the optimal selection and task oriented programming of cooperating devices in the robot cell. These devices and the products to be manufactured are Cyber-Physical-Systems (CPS), which possess individual virtual models of their requirements and abilities. Based on the communication between the CPS and the fusion of their models, the feasibility of the required assembly tasks with the devices available in the robot cell is determined. The product description is used to optimally assign the required assembly processes to cooperating devices in the robot cell and allows an automated planning and execution of all required tasks. This work presents the overall system architecture, the necessary subsystems and the various models in the virtual representations of the devices and products for a sufficient description of the conditions of entire robot cell to reach the before mentioned goals. © 2015 Elsevier Ltd.


Fischbach C.W.P.,Institute for Machine Tools and Industrial Management
Advanced Materials Research | Year: 2013

Models to assess the maturity of a technology are commonly used in the aerospace sector. They give insights about technological risks and help to time the integration of new technologies to ensure their safe usage for society. Those models can also generate benefit for other sectors, such as the general mechanical engineering sector, when it comes to the assessment of new and complex technologies. One example of such a complex technology is carbon composite material. It offers big potentials (e.g. light weight and excellent dynamic behaviour) on the one hand, but raises many technological and economic issues (e.g. missing connecting concepts as well as new process chains and costs) on the other. This article discusses the state of the art of models to assess a technology's maturity. It further presents a method to assess the maturity of carbon composite components for their usage in general engineering applications. The first results show significant differences in the maturity profiles of the different carbon composite components even though the material is the same. This implies that materials cannot be evaluated solely, because the interdependencies with manufacturing techniques and component design have to be taken into account. © (2013) Trans Tech Publications, Switzerland.


Jelinek M.,Institute for Machine Tools and Industrial Managemenet | Schilp J.,Institute for Machine Tools and Industrial Managemenet | Reinhart G.,Institute for Machine Tools and Industrial Management
Procedia CIRP | Year: 2015

The current development trend in automotive engineering as well as in aviation features an increased substitution of metal components by carbon fibre reinforced plastic (CFRP) structures. However, material-specific requirements make a complete replacement of a metal construction by CFRP structures impracticable. Consequently, metallic regions remain in the CFRP base body as metal joints or reinforcements. Frequently, these hybrid transition areas are involved with an increased quality concern. This research explores the methodological deduction of test specimens which allow an thermographic investigation of typical defects based on predefined industrial CFRP machine elements concretely (shaft coupling, hollow shaft, gripper arm). Thereby, the optimisation through systematic parameter variation and the structured parameter documentation in a database are focused within the present research. By deriving inspection task-specific user guidelines, the predominantly manual thermographic testing process can be considerably accelerated. © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license.


Krotil S.,Fraunhofer Institute for Machine Tools and Forming Technology | Reinhart G.,Fraunhofer Institute for Machine Tools and Forming Technology | Reinhart G.,Institute for Machine Tools and Industrial Management
Procedia CIRP | Year: 2016

Shorter product life cycles as well as growing range of product varieties are shifting the product development in the focus. Furthermore, risks of new developments can be reduced by evaluating different solutions. An effective instrument for the validation of different concepts and designs is simulation. Nowadays, there is a huge drawback in the area of fluid simulations. Tools used in the area of Computations Fluid Dynamics (CFD) have two disadvantages: on the one hand it takes a lot of effort to prepare the simulation; on the other hand, the computational execution of simulation takes a long time. Thus, fluids are mainly simulated in special cases like aerodynamics, not in special cases like filling processes because of not being economical. We present a new approach for simulating fluids in the early phases of the product development process based on existing Lagrangian methods. In addition a new method for a fast generation and modification of simulation models is described. We evaluate the new method for online simulation in an example showing a design process with a real-time simulation of the design, which is updated online. Thus, the design of products is supported by the What-You-See-Is-What-You-Get approach, helping to reduce the effort put into different concepts. © 2016 The Authors.


Schmutzler C.,Institute for Machine Tools and Industrial Management | Zimmermann A.,University of Passau | Zaeh M.F.,Institute for Machine Tools and Industrial Management
Procedia CIRP | Year: 2016

3D printing is a common technique for producing complex parts or molds in a small series scale by using ink-jet technology. The size accuracy is of great importance for the use of this technology in the manufacturing sector. However, the chemical solidification reaction of the powder with the binder during the fabrication of parts results in shrinkage. Warpage results whenever shrinkage does not occur uniformly throughout the entire part. Consequently, the size deviation is a result of the layer-wise printing process and the inhomogeneous shrinkage. A possibility to reduce these deviations is a pre-deformation of the part data, contrary to the expected defect. This is implemented by using a free-form deformation (FFD) approach. The FFD deforms the surrounding cuboid of an object in order to adapt the embedded object. Thus, an increased size accuracy is achieved by choosing suitable parameters for the FFD. This paper describes the implementation of the FFD to compensate the significant, frequently appearing defects in the 3D printing process. The relevant defect types and typical values for the deviation are presented. Furthermore, factors of influence are identified and the deviations are described by mathematical functions. These functions are transferred to an application for the FFD. The effect of the FFD is shown for reference parts and suitable compensation parameters are presented. Finally the knowledge-based transfer to related geometries is investigated and the effect of the compensation is discussed. © 2016 The Authors.

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