Embedded vision device integration via OPC UA: Design and evaluation of a neural network-based monitoring system for Industry 4.0 - Oks, Sascha Julian; Zöllner, Sebastian; Jalowski, Max; Fuchs, Jonathan; Möslein, Kathrin (Procedia CIRP, 2021)
Sensor application is a basis for digitized industrial value creation. However, for existing production and logistics systems, sensor retrofitting is accompanied by challenges, including plant heterogeneity and lack of standards. This work addresses this issue through the design, implementation and evaluation of an embedded vision high-bay shelf monitoring system of an Industry 4.0 demonstrator. Utilizing design science research methodologies, the artifact unites the concepts of computer vision, convolutional neural networks and OPC UA for widely applicable and cost-efficient retrofitting. Design principles derived from the artifact’s design and evaluation cycles can serve as abstracted guidelines for designing retrofit visual sensor system
Keywords: Embedded vision; Retrofitted sensor systems; Neural networks; OPC UA; Industry 4.0

Enabling deep learning using synthetic data: A case study for the automotive wiring harness manufacturing - Nguyen, Huong Giang; Habiboglu, Resul; Franke, Jörg (Procedia CIRP, 2022)
The wiring harness manufacturing follows a high-variant manufacturing philosophy with a high degree of manual labor to produce customized products. Therefore, the process step of optical inspection is crucial to monitor, assess, and proactively safeguard the quality of produced wiring harnesses. To automate the optical inspection, which is currently manually conducted by operators, deep learning has become a powerful algorithm outperforming traditional computer vision approaches. Deep learning-based automated optical inspection systems can robustly and reliably detect rigid and deformable components, such as connectors, clips, single wires, and wire bundles. However, the bottleneck for scalable deep learning solutions in the industrial environment and high deep learning model performance is the database for model training and optimization. To address this research gap, we propose a deep learning-based data processing pipeline for automated optical inspection of wiring harnesses using real and synthetically generated point clouds. This paper outlines the process of real and synthetic data generation and evaluates the potential of synthetic data to enrich real data for model training. The data processing pipeline is implemented and experimental findings are generated to deduct important parameters for synthetic data generation and deep learning model training which impact model performance.<br
Keywords: Wiring Harness; Deep learning; Point clouds; Synthetic data; Domain gap

Enabling Live Data Controlled Manual Assembly Processes by Worker Information System and Nearfield Localization System - Fischer, Christian; Lusic, Mario; Faltus, Florian; Hornfeck, Rüdiger; Franke, Jörg (Procedia CIRP, 2016)
Abstract Existing localization solutions cannot be directly integrated into production systems. This article describes a nearfield localization system which can be installed on tools due to its small dimensions. Live data controlled manual assembly processes are enabled. In combination with worker information systems, the manual assembly process can be supported more precisely compared to common systems. The benefits are shown within product-specific assembly scenarios. One benefit is enabling work out of sight (non-visible range) guided through a virtual model on a screen. Error prevention (zero-defect assembly) can be realized by monitoring and matching the actual position to the assembly location. Even without augmented reality devices, comparative 3-D representations of real and virtual world are feasible, supporting employees in mobile workshop with complex repairs. In particular, difficult accessibility can be easily determined when carrying out maintenance work by knowing the complete product structure.
Keywords: Assembly; Information; Worker information system; Nearfield localization

Energetic Simulation of Complex Mechatronic Drive Systems over Complete Drive Cycles - Hörlin, Sebastian; Dietz, Armin; Hubert, Markus; Franke, Jörg (Applied Mechanics and Materials, 2015)
This paper presents a simulation model, which enables the energetic simulation of complex mechatronic powertrains over complete drive cycles. One focus of this work is on reducing the simulation duration to enable the simulation of extended drive cycles on the one hand, and the possibility to optimize drive cycles on the other hand. Furthermore, the program allows the user to assemble an energetically optimized selection of propulsion components.

Energieeffiziente Raumbelüftung mit Wärmerückgewinnung unter Verwendung eines neuartigen Wirkprinzips - Praß, Julian; Bürner, Johannes; Franke, Jörg (Umwelt-Technologie und Energie in Bayern, 2018)

Energieprognose mittels Methods-Energy Measurement - Berücksichtigung des Energiebedarfs in der frühen Planungsphase durch komponentenbasierte Energieplanung - Bornschlegl, Martin; Bregulla, Markus; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Eine frühzeitige Berücksichtigung des Energieverbrauchs im Planungsprozess ist sowohl ökologisch als auch ökonomisch sinnvoll. Dazu sind allerdings aussagekräftige Daten nötig, welche zu diesem Zeitpunkt oftmals noch nicht bereit stehen. Aus diesem Grund wurde der Methods-Energy Measurement-Ansatz konzipiert, damit eine ganzheitliche energetische Betrachtung der Fertigungsanlage über ihren Lebenszyklus im Planungsprozess erfolgen kann.
Keywords: Energieplanung

Energieprognose mittels Methods-Energy Measurement: Berücksichtigung des Energiebedarfs in der frühen Planungsphase durch komponentenbasierte Energieplanung - Bornschlegl, Martin; Bregulla, Markus; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
The reduction of energy costs of manufacturing technologies is both an important and current objective for factory operators. To achieve an estimation of the energy consumption in an early planning stage, a suitable forecast approach is required. This article shows how the prospective energy consumption can be determined by using Methods-Energy Measurement. This method contributes to identify and realize sustainable solutions in advance and as a result, increases the profitability of a factory.
CRIS-Team Scopus Importer:2023-03-07

Energieverbräuche in der Kosten- und Leistungsrechnung - Rackow, Tobias; Götz, Johannes; Schuderer, Peter; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Especially in price sensitive and energy intensive sectors, rising energy costs lead to a differentiated handling of companies with their energy demands. Supported by energy management systems, companies gain more and more transparency over their energy consumptions. This article describes how this transparency can be utilized within the field of cost accounting, in order to evaluate the economic efficiency of the produced products.
CRIS-Team Scopus Importer:2023-03-07

Energy consumption and dynamic behavior analysis of a six-axis industrial robot in an assembly system - Paryanto, Paryanto; Brossog, Matthias; Kohl, Johannes; Merhof, Jochen; Spreng, Simon; Franke, Jörg (Procedia CIRP 23, 2014)
This paper presents an experimental study to validate a dynamic model of a six-axis industrial robot as part of an assembly system and to analyze its power consumption as well as its dynamic behavior. Furthermore, the effect of robot operating parameters (i.e., payload and speed) on the power consumption and the dynamic behavior are analyzed. The investigation shows that the comparative study between simulation and experimental results can be used to improve the model's accuracy and prove that the simulation model represents the real system. Both simulation and experimental results show that the robot operating parameters strongly influence the industrial robot's power consumption and dynamic behavio
Keywords: Energy simulation; Industrial Robot; Systems Engineering

Energy Consumption Modeling of a Turning Table and Standardized Integration into Virtual Commissioning - Hauf, Dominik; Kruck, Julian; Paryanto, Paryanto; Franke, Jörg (Procedia Manufacturing, 2017)
This paper describes the standardized integration of energy models into the virtual commissioning tool chain for a holistic energy consumption and peak power simulation of production cells used in the automotive industry. An energy model of a turning table as part of a demonstration cell is built in detail using modeling language Modelica. Further, an interface description for model connection to virtual commissioning is presented. Finally, simulation results are validated by measurements on a real demonstrator.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficency; functional mock-up interface (FMI); physics based modeling; sustainable manufacturing; virtual comissioning

Energy consumption modeling within the virtual commissioning tool chain - Hauf, D.; Meike, D.; Paryanto, Paryanto; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2015)
In this paper an energy modeling approach within the virtual commissioning tool chain is presented. Virtual commissioning (VCom) today is a de facto methodology for programmable logic controller (PLC) software design and validation for automatic production systems. Energy consumption has never been an optimization criterion in VCom. Concepts of energy consumption modeling for any production unit have been investigated for measuring, visualization and optimization of control strategies. The hardware-in-the-loop simulation includes logical behavior models, the respective energy models and 3D-kinematic models of the production units, which are connected over common industrial bus network with a hardware-PLC. The concept has been developed for use with commercially available software tools so that the research results are implementation-oriented. An example from the automotive industry has been used.
CRIS-Team Scopus Importer:2023-03-07

Energy controlling - Analysis and evaluation of energy measuring equipment for the purpose of energy transparency in production plants - Rackow, Tobias; Javied, Tallal; Geith, Teresa; Schuderer, Peter; Franke, Jörg (Applied Mechanics and Materials, 2014)
This paper addresses the analysis and evaluation of energy measuring devices for the operation in the manufacturing industry. The focus lies on the comparison and scoring of energy meters regarding their performance spectrum against the backdrop of an energy controlling. Based on the fundamentals of electro technical metrology, the main measurement parameters were identified which are necessary for the purpose in the manufacturing industry. Further, capability characteristics for the differentiation of electricity meters were defined. With this, a classification of meters into a basic, a standard, an advanced and a premium class was undertaken. It is shown, that the advanced class is sufficient for the permanent monitoring of electricity consumption in the lights of energy controlling.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy controlling; Energy efficiency; Energy measuring equipment

Energy efficiency investigation on high-pressure convection reflow soldering in electronics production - Esfandyari, Alireza; Syed Khaja, Aarief Hussain; Javied, Tallal; Franke, Jörg (Trans Tech Publications Ltd, 2014)
One of the key factors in efficient and defect-free electronics manufacturing is the soldering of electronic components to the printed circuit boards. The deciding factor in the reliability and lifetime of the product is the quality of the soldered interconnections. The setting up of the reflow soldering profile plays a crucial role in the electrical functionality and robustness of the product. Especially the miniaturization of the assemblies and the development of new materials make it inevitable for the definition of new processes, optimization and implementation. In this paper, the combination of over-pressure and convection reflow soldering to minimize the defect rate and the related energy analysis for energy efficiency will be discussed and presented. An analysis with variations in solder time, cost, energy, quality trade-off in the over-pressure reflow soldering process for classical printed circuit boards (PCBs) has been demonstrated.
Keywords: Convection reflow soldering; Electronics production; Energy efficiency; Over-pressure

Energy efficient processes of electric motor manufacturing - Kühl, Alexander; Kreitlein, Sven; Höft, Annika; Franke, Jörg (2018 IEEE Texas Power and Energy Conference (TPEC), 2018)

Energy-efficient production strategies and technologies for electric drives - Franke, Jörg; Kreitlein, Sven; Risch, Florian; Günther, Stefan (Proceedings of the IEEE International Conference on Industrial Technology, 2013)
Due to the scarcity of resources the sustainable production of electric drives has become more and more important. In the context of a potentially huge increase in the demand for electric traction drives by the market of e-mobility, this topic is even more challenging. For this, new topologies with lower requirements for the needed valuable resources, new energy efficient drive concepts, optimized production, and logistic processes in terms of their resource requirements and integrated recycling strategies are presented in this paper. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07

Energy-efficient room ventilation with heat recovery using a novel concept - Praß, Julian; Bürner, Johannes; Franke, Jörg (Environment and Energy in Bavaria, 2018)

Energy flexible production: Saving electricity expenditures by adjusting the production plan - Rackow, Tobias; Kohl, Johannes; Canzaniello, A.; Schuderer, P.; Franke, Jörg (Procedia CIRP, 2015)
The energy turnaround in Germany increases the share of renewable energies. Since the amount of renewable energy supply is immanently subject of variation, the electricity price at the European Energy Exchange EEX is highly volatile. If companies would purchase the electricity directly at the EEX instead of from a wholesale power supplier along with price fixing, companies would benefit from increasing production in times with low electricity costs and reducing production in high-cost times. This paper shows, that influencing respectively shifting the time of electricity consumption -e.g. by adjustment of process parameter, shift period, order of jobs or machine utilization, by pausing of processes or delaying of job starts - can theoretically reduce electricity expenditures. The measures are being explained and discussed, followed by a description of company in-house and external requirements for the energy flexible production.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy expenditures; Energy flexibility; Energy management; Factory control; Flexible production

Energy KPI’s, challenges for sustainable manufacturing strategies, analysis of existing rules and indicators in an industrial environment in relation to the establishment of energy benchmark - Kreitlein, Sven; Rackow, Tobias; Franke, Jörg (Advanced Materials Research, 2014)
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.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy benchmark; Energy efficiency; Production

Energy Planning of Manufacturing Systems with Methods-Energy Measurement (MEM) and Multi-Domain Simulation Approach - Bornschlegl, Martin; Paryanto, Paryanto; Spahr, Michael; Kreitlein, Sven; Bregulla, Markus; Franke, Jörg (Applied Mechanics and Materials, 2014)
Energy costs play a decisive role in the operation costs of automotive production companies. Therefore, energy planning in an early conception and planning stage becomes an important topic. This is because the early conception and planning stage has the greatest potential to influence the energy consumption of manufacturing technologies since about 70-80 % of the energy costs are committed during this stage. However, lifetime cost and specifically energy consumption are currently not a determining factor at this stage. The reason is that the prediction of energy costs for complex manufacturing systems are challenging. Previous research approaches in the area of energy planning are limited to detailed planned production. A standardized approach to determine the energy consumption rates at an early stage does not exist. In this context, the EffiPLAS project has therefore proposed to solve this challenge. The aim of this project is to develop a Methods-Energy Measurement approach with elementary energy elements to support the planning process at an early stage, and to develop a modular simulation model for calculating the energy consumption of industrial robots, which complements the energy prediction. In this paper, the basic concept of elementary energy units and their value determination techniques are presented, and the simulation model is outlined. The developed approach will help to predict the prospective energy consumption of complex production equipment so that energy costs can be accounted for in an improved manner within a life-cycle cost comparative analyses.
Keywords: Energy consumption; Energy efficiency; Energy simulation; Industrial robots; Methods-energy measurement (MEM); Production planning

Engineering von mechatronischen Baugruppen für die additive Fertigung - Zeitler, Jochen Tobias; Kühn, Cornelius; Urban, Nikolaus; Franke, Jörg (Konstruktion, 2017)
Als Reaktion auf den wachsenden Einfluss der Mechatronik auf die Industrie ist die additive Fertigung inzwischen so weit entwickelt, dass sie dazu in der Lage ist, die Bedürfnisse von räumlichen, hochintegrierten und interdisziplinären Baugruppen zu erfüllen. In Form eines hybriden, rein additiven Fertigungsprozesses können sowohl mechanische Substratkörper, elektrisch leitfähige Strukturen, sowie Inlets, die während des Fertigungsprozesses integriert werden, in einem einzigen Prozess zu einer Baugruppe kombiniert werden. Um diesen neuartigen Engineeringprozess zu unterstützen, werden innovative Ansätze und Werkzeuge der Konstruktionsmethodik vorgestellt.
Keywords: 3D-Druck; Konstruktion; Produktentwicklung; MID; CAD; Elektronik; Mechatronik

Enhanced Organizational Ambidexterity in Electronics Manufacturing through the Automation of Production-Related Processes - Bogner, Eva; Kästle, Christopher; Franke, Jörg (Proceedings of the 6th International Conference on Industrial Engineering and Operations Management, 2016)
The current discussion about the industrial Internet of Things (IoT) focuses in particular on diverse technologies and their possible applications in companies. However, the actual potential benefits and objectives of the fourth industrial revolution for companies are often neglected. The challenges posed by the increasing number of variants and decreasing batch sizes up to batch size one require special adaptability and flexibility. The aim is not only to offer customized products, but also to produce them with the efficiency of a mass production. This affects numerous business sectors. Whereas in the past the search for efficiency potentials was focused on the production process, it is now essential to consider strategic and operational corporate areas beyond production – the so-called overhead processes. The required flexibility of companies to produce mass-customized goods leads to an increased complexity of internal processes and a high proportion of additional overhead activities for the management of resources. In this paper, we provide an approach to automate repetitive, non-creative activities in all value added processes and to connect overhead processes with the production so that a fast, automated response to unplanned events in production is facilitated. Hence, an economical production can be realized in the context of mass customization.
Keywords: Industrial internet; Automation; Efficiency potentials; Potential benefits; Value-added processes; Electronics manufacturing

Enhanced X-Ray Inspection of Solder Joints in SMT Electronics Production using Convolutional Neural Networks - Schmidt, Konstantin; Thielen, Nils; Voigt, Christian; Seidel, Reinhardt; Franke, Jörg; Milde, Yannik; Bonig, Jochen; Beitinger, Gunter (2020 IEEE 26th International Symposium for Design and Technology in Electronic Packaging (SIITME), 2020)
The electronics production is prone to a multitude of possible failures along the production process. Therefore, the manufacturing process of surface-mounted electronics devices (SMD) includes visual quality inspection processes for defect detection. The detection of certain error patterns like solder voids and head in pillow defects require radioscopic inspection. These high-end inspection machines, like the X-ray inspection, rely on static checking routines, programmed manually by the expert user of the machine, to verify the quality. The utilization of the implicit knowledge of domain expert(s), based on soldering guidelines, allows the evaluation of the quality. The distinctive dependence on the individual qualification significantly influences false call rates of the inbuilt computer vision routines. In this contribution, we present a novel framework for the automatic solder joint classification based on Convolutional Neural Networks (CNN), flexibly reclassifying insufficient X-ray inspection results. We utilize existing deep learning network architectures for a region of interest detection on 2D grayscale images. The comparison with product-related meta-data ensures the presence of relevant areas and results in a subsequent classification based on a CNN. Subsequent data augmentation ensures sufficient input features. The results indicate a significant reduction of the false call rate compared to commercial X-ray machines, combined with reduced product-related optimization iterations.<br
Keywords: Inspection; Training; Soldering; X-ray imaging; Production; Image classification; Object detection; electronics production; automated X-ray inspection; machine learning; computervision; Convolutional Neural Networks

Enhancing Flexibility in Power Electronics Production: A Study on Robotic Handling of Copper Clips for Laser Bonding - Ockel, Manuela; Janisch, Lucas; Franke, Jörg; Schlichting, Johannes; Breuer, Marius (11th International Conference on Control, Mechatronics and Automation, ICCMA 2023, 2023)
Keywords: semiconductor device packaging; power electronics; robotics; laser bonding; gripper

Enhancing Men’s Health Management at Home with an Easy-to-Use, App-Connected Prostate Self-Testing Device - Benke, Elisabeth; Gschaidmeier, Simone; Gentsch, Olivier; Deittert, Hannes; Martin, Sina; Preis, Alexander; Franke, Jörg (Proceedings of the 16th International Joint Conference on Biomedical Engineering Systems and Technologies BIOSTEC, 2023)
A fundamental problem in men's health is that large groups of men shy away from visiting the doctor, and specifically, often do not take part in early screening tests if they do not have complaints yet. This is particularly evident in the sensitive field of urology. Benign prostatic hyperplasia (BPH) is one of the most widespread disorders in ageing men and is associated with an increasing burden on healthcare systems. It is often underdiagnosed and undertreated and has a substantial impact on the patients’ quality of life. An altered urine flow curve can be a first clue to BPH. A new developed, easy-to-use prostate self-testing device based on a Swiss high-precision flowmeter enables men to check their urine flow at home in familiar surroundings. Via a Bluetooth connection, the results can be transmitted wirelessly and stored in a digital diary so that longterm developments can be tracked. The self-testing device not only provides men with the opportunity to deal with their health with low effort and in a discreet way, but also gives them certainty about their prostate health status.
Keywords: Urology; Uroflowmetry; Benign Prostatic Hyperplasia; Prostate Conditions; Men’s Health

Enhancing Sustainability and Resilience through Business Model Innovation for Electrical Engineering SMEs - Bründl, Patrick (2023)
This case study explores how a German control cabinet and electrical engineering SME has successfully navigated the challenges of intense competition and skilled labor shortages in the manufacturing sector. It focuses on their adoption of a circular economy model in response to the growing problem of electronic waste (e-waste), which has seen a significant global increase. The company's approach centers on reuse, remanufacturing, and recycling of materials, reducing environmental impact and raw material costs. This strategy has not only provided economic benefits and enhanced supply chain resilience during crises like the COVID-19 pandemic but also integrated advanced technologies for improved efficiency in recycling processes. The case study illustrates the critical role of sustainable practices and technological adaptation in ensuring the long-term success and competitiveness of SMEs in the global market.<br

Entstörungsstrategie für autonome mobile Roboter Intervention strategy for autonomous mobile robots - Blank, Andreas; Berg, Julia; Zikeli, Georg Lukas; Lu, Shuang; Sommer, Oliver; Reinhart, Gunther; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Die Produktion ist geprägt durch einen Antagonismus aus Flexibilität und Produktivität. Autonome Roboter mit maschinell erlernten Fähigkeiten weisen Potenzial auf, das Spannungsfeld zu entlasten. Allerdings bedarf es aufgrund von Fehleranfälligkeit solcher Systeme Strategien zur Entstörung. Im Beitrag vorgestellt werden Methoden für die Vorortunterstützung mittels Werkerführung sowie zur Entstörung aus der Ferne mittels Teleoperation. Production is characterized by an antagonism between flexibility and productivity. Autonomous robots with learned skills show potential for relieving existing challenges. However, present failure susceptibility requires efficient intervention strategies to allow a technology establishment. This paper presents methods for on-site support based on a factory worker guidance system as well as remote assistance through teleoperatio
Keywords: Automatisierung; Industrieroboter; Mensch und Technik; Teleoperation

Entstörungsstrategie für autonome mobile Roboter/Intervention strategy for autonomous mobile robots - Blank, Andreas; Berg, Julia; Zikeli, Georg Lukas; Lu, Shuang; Sommer, Oliver; Reinhart, Gunther; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Production is characterized by an antagonism between flexibi-lity and productivity. Autonomous robots with learned skills show potential for relieving existing challenges. However, pre-sent failure susceptibility requires efficient intervention strate-gies to allow a technology establishment. This paper presents methods for on-site support based on a factory worker guidan-ce system as well as remote assistance through tele-operation.
CRIS-Team Scopus Importer:2021-04-19

Entwicklung einer Methodik zur ressourcenorientierten Steuerung der Werksprozesse in der Kalksandstein-Industrie: "KS-Sim" - Donhauser, Toni; Eden, Wolfgang; Franke, Jörg; Jung, Tobias; Schuderer, Peter (2015)

Entwicklung und Erprobung einer kosten- und funktionsoptimierten, mechatronischen Unterarmprothese - Yoo, In Seong; Scheithauer, Ellen Corinna; Sesselmann, Stefan; Franke, Jörg (3. Transdisziplinäre Konferenz – Technische Unterstützungssysteme, die die Menschen wirklich wollen, 2018)

Entwicklung und Evaluierung eines Systems zur automatisierten Prüfung von im Plasmabeschichtungsprozess additiv gefertigten Leiterbahnstrukturen für elektronische Baugruppen - Hahn, Dorothea; Braun, Thomas; Franke, Jörg (Elektronische Baugruppen und Leiterplatten EBL 2018, Multifunktionale Aufbau- und Verbindungstechnik – Beherrschung der Vielfalt, 2018)

Environment representation and path planning for unmanned aircraft in industrial indoor applications - Lieret, Markus; Kalenberg, Matthias; Hofmann, Christian; Franke, Jörg (FAIM 2021, 2021)
CRIS-Team WoS Importer:2022-10-28

Erkenntnisse aus der Biegesimulation von Flachdraht - Weigelt, Michael; Fröschl, Christian; Masuch, Michael; Riedel, Andreas; Franke, Jörg (Draht, 2018)
<span style="background-color: transparent; color: rgb(102, 102, 102); font-family: Georgia, "Times New Roman", serif; font-size: 14px; font-style: italic; font-variant-numeric: normal; font-variant-east-asian: normal; line-height: 20px;">Dank einer simultanen Entwicklung aus struktur-mechanischer FE-Simulation und Versuchserkenntnissen lassen sich Formspulen von Traktionsmotoren kosten- und zeiteffizienter gestalten und innerhalb eines definierten Prozessfensters fertigen.

Erzeugung von 3D-Funktionsstrukturen fuer Hochfrequenzanwendungen durch Druckverfahren - Ankenbrand, Markus; Franke, Jörg; Lomakin, Konstantin; Pavlenko, Tatiana; Sippel, Mark; Gold, Gerald; Weidner, T; Weiß, D; Helmreich, Klaus (PLUS - Produktion von Leiterplatten und Systemen, 2018)

Evaluating thermoset resin substrates for 3D mechatronic integrated devices and packaging - Häußler, Felix; Shen, Shengxia; Petillon, Simon; Weser, Sascha; Haybat, Mehmet; Eberhardt, Wolfgang; Zimmermann, André; Franke, Jörg (International Symposium on Microelectronics, 2020)
Miniaturization efforts and increasing demands regarding reliability of mechatronic systems require new materials and processes for the 3D mechatronic integrated devices (3D-MID) technology. Currently, in the area of 3D-MID mostly thermoplastic materials are in use in the industry, which are metallized using the LPKF-LDS® process. This paper is supposed to demonstrate the eligibility of thermoset resins as a new material class for 3D-MID applications and as a packaging option for silicon chips which are currently encapsulated using transfer molding of thermosets. The reliability of the conductor tracks made using a LDS-additive free process as well as the adhesion forces are investigated. Different laser parameters for structuring of two different substrate materials are compared. For reliability testing a thermal shock test is applied. Furthermore, the adhesion is tested using Hot-Pin-Pull testing. The conductor tracks surpass 2000 cycles thermo-mechanical load without showing strong deterioration of the track resistivity. The incorporated approach enables electrically reliable functionalization of packaged dummy chips including vias for connection to terminals on the chips. The results of the tested injection moldable thermoset resins are comparable to state-of-the-art 3D-MID thermoplastic substrates and thus, suited as circuit carrier material in electronic packaging.<br

Evaluation and Assessment of Additive Manufacturing Processes Based on the Least Energy Demand in Application for Sustainable Production - Kreitlein, Sven; Urban, Nikolaus; Gerter, Viktor; Franke, Jörg (Applied Mechanics and Materials, 2017)

Evaluation and Characterization of 3D Printed Pyramid Horn Antennas utilizing different Deposition Techniques for Conductive Material - Lomakin, Konstantin; Pavlenko, Tatiana; Ankenbrand, Markus; Sippel, Mark; Ringel, Johannes; Scheetz, Matthias; Klemm, Tobias; Gräf, Daniel; Helmreich, Klaus; Franke, Jörg; Gold, Gerald (IEEE Transactions on Components, Packaging and Manufacturing Technology, 2018)
This paper evaluates different metal deposition approaches for a two-staged additive manufacturing (AM) process for 3-D horn antennas, divided into the deposition of plastic and conductive material. The demonstrated fabrication workflow allows for antennas of low cost and low weight and, therefore, demonstrates the vast benefit of AM. The comparison of a commercially available cast aluminum horn to the fabricated prototypes reveals a deviation of up to 3 dB in terms of transmission losses in copolarization over a distance of 1.85 m. Cross-polarization measurements are presented revealing a larger variation among the different metallization approaches. The results shown in this paper demonstrate a successful application of AM in radio frequency engineering. Moreover, one of the presented approaches makes use of only 3-D printing systems and is, therefore, potentially suitable for totally automated manufacturin
lhft_intern.bib::Lomakin2018g

Evaluation der virtuellen Absicherung hybrider Montagesysteme mittels Kinematik- und Ergonomiesimulationswerkzeugen - Metzner, Maximilian; Heinlein, Pascal; Wytopil, Benedict; Donhauser, Toni; Franke, Jörg (ASIM 2019, 2019)

Evaluation of an algorithm for optical pulse detection in children for application to the Pepper robot - Goes, Nina; Kirst, Simone; Seßner, Julian; Steffan, Jan; Struck, Matthias; Franke, Jörg; Naumann, S.; Dziobek, I.; Lang, Nadine; Wittenberg, Thomas (Current Directions in Biomedical Engineering, 2021)
To engage in socio-emotional interactions, children with autism spectrum conditions (ASC) need support to understand and convey emotions. In our approach, a humanoid robot (Pepper, Softbanks Robotics) acts as a tutor for the child within autism care. The robot, equipped with multimodal sensor technology to acquire the emotional feedback of the child, stimulates the child to perform tasks, adapted to its current arousal state. By in-, or decreasing the difficulties of implemented training modules, the child can be given the appropriate task according to its emotional state. The child's arousal is measured with different techniques implemented in and on the robot: emotion detection based on audio recordings of the speech signal and camera detected facial expressions, or heart rate. To this end, the remote Photoplethysmography (rPPG) signal from camera recordings of the subjects' face is acquired. While its unintrusive measurement is an advantage, a major drawback for rPPG is its proneness to motion and light artefacts requiring de-noising steps. A wavelet transform based on log-Gabor wavelets and a filter bank with 32 filters was implemented. The signal was filtered with a prior filter and afterwards with a Markov chain in order to extract the underlying pulse rate. Within an initial study, five children were observed watching videos with different co-notated emotions. As reference for the heart rate (HR), a wristband (empatica E4) was used. The captured emotions of all subjects were annotated to identify low and high arousal parts and positive and negative emotions. Extracted HR from rPPG-data indicated a correlation with the annotated emotions.
CRIS-Team Scopus Importer:2023-03-07
Keywords: autistic children; optical pulse assessment; rPPG; social robotics

Evaluation of deep learning for semantic image segmentation in tool condition monitoring - Lutz, Benjamin; Kißkalt, Dominik; Regulin, Daniel; Reisch, Raven; Schiffler, Andreas; Franke, Jörg (2019 18th IEEE International Conference On Machine Learning And Applications (ICMLA), 2019)

Evaluation of detatchable board-to-board interconnects on screen printed electronic structures - Schirmer, Julian; Huemmer, Michael; Klauss, Matthias; Neermann, Simone; Reichenberger, Marcus; Franke, Jörg (Flexible and Printed Electronics, 2021)
Hybrid printed electronics (HPE) combines advantages of conventional electronics manufacturing technologies such as surface mount technology with those of printed electronics in order to realize more complex electronic systems. To realize the final product, such HPE subassemblies have to be connected to higher-level assemblies. So far interconnection techniques for the so-called level 3 interconnection between printed subsystems and standard electronics have not yet been considered adequately in scientific research. In this paper, alternative detachable level 3 interconnection technologies, i.e. spring loaded contact pins, zero insertion force (ZIF) as well as Non-ZIF connectors are investigated systematically regarding their electrical behaviour against the background of printed electronics. Screen-printed silver filled polymer thick film paste is used to realize printed conductor patterns on flexible polymer substrates, which are connected later on with the alternatives mentioned above. Transition resistance is measured using the four wire method as produced, after repeated mating cycles as well as after accelerated aging tests. The various electrical contacts are subjected to thermal stress in temperature cycling testing and during aging at a constant high temperature. As a result it can be stated, that the sping-loaded contact pins used in this investigation show superior behavior compared with the selected connectors in terms of resistance increase after mating cycles. Concerning long-term behavior after thermal cyling and high temperature storage, all investigated alternaives reveal convincing results.
CRIS-Team WoS Importer:2021-09-24

Evaluation of different methods for removing the conductor insulation of stranded conductors - Riedel, Andreas; Hahn, Roman; Kühl, Alexander; Franke, Jörg (12th International Symposium on Advanced Topics in Electrical Engineering, ATEE 2021, 2021)
The ecological change in society and politics leads to an increased demand for alternative drives. In the field of mobility, this can be observed by ongoing innovations in research and development as well as in the production of electric machines. Currently, the automotive industry is focusing more and more on traction drives using hairpin technology. The reasons for this are the easier automation of the manufacturing process and the higher copper filling factors that can be achieved. The latter help to improve the power density. At high frequencies, which inevitably occur in high-speed applications, large conductor dimensions lead to additional losses due to eddy currents. To reduce these losses, twisted round wires can be used instead of flat conductors. Nevertheless, the manufacturing as well as the processing of this semi-finished product is more complex. The aim of this paper is to present and compare the possibilities for removing the required tape of the stranded conductor and to substantiate it with initial results. For this purpose, the general production chain of a hairpin stator is explained at the beginning of the paper in order to show the reasons why the removal of the bandage is of elementary importance. This is supplemented by technological aspects of stranded wire technology which cause-effect relationships serve as the basis for the main part of this paper.
CRIS-Team Scopus Importer:2021-06-11
Keywords: Electric traction drives; Hairpin winding; Insulation material; Litz wire; Skinning methods; Stranded conductors

Evaluation of economic and ecologic potential of induction heating in the context of insulation systems within electric drives - Hofmann, Benjamin; Spreng, Simon; Kühl, Alexander; Franke, Jörg (IEEE Electrical Insulation Conference, 2015)
Resin applications have always been found within the production of electric drives. Replacing natural materials like tar and rubber, industrial produced polymers quickly spread amongst all major components and manufacturing steps of electric machines. Today, thermosetting resins are mainly used within the disciplines of insulation and fixation of materials, manifesting in wire enamels, impregnation varnishes, potting resins and thermally curing adhesives. Numerous variations in topology create various challenges around these products. Thermal curing generally uses an excessive amount of energy when being conducted by oven heating or infrared radiation. Alternative and particularly energy-efficient technologies are available, but have yet to be investigated from a scientific perspective. Within the research project E vertical bar Solation, the E vertical bar Drive-Center at the institute FAPS of the Friedrich-Alexander-University of Erlangen-Nuernberg has aimed to investigate induction heating technology as an energy-saving method for thermosetting resin and powder coat curing to create insulating layers within an automated and flexible production of electric drives. Saving potential in the context of electrical sheet laminations has shown to be as high as up to 95% of electrical energy. In order to determine the value of this technology, simulative as well as empiric investigations have to be made to create a better understanding of how induction heating of sheet lamination works and to determine feasibility and integration into current production processes. The paper will present the latest outcomes of energy-focused value stream methods in order to determine applicable scenarios and production thresholds, in which induction heating can be a viable alternative to current heating technologies. In parallel, a simulative approach is under development to determine temperature distribution during heating process of laminated cores. The project aims for an extensive and fundamental knowledge of the process itself in order to determine optimal heating times and maximum efficiency.
Keywords: insulation; resin; induction heating

Evaluation of energy efficient joining processes in the field of electric drives manufacturing considering quality aspects - Spreng, Simon; Risch, Florian; Glabel, Tobias; Wolff, Josse; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
The implementation of green products and matching manufacturing processes increasingly attract public attention. Therefore, the institute FAPS analyzed the joining process as it is identified to be one of the major energy consumers in the context of electric drives manufacturing. The present approach introduces a statistically developed methodology to predict the energy consumption and the resulting connection quality of one of the major, currently available joining techniques. Therefore an analytical model was developed, which was afterwards used to optimize the parameter settings of an industrial cooperation partner.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric drives manufacturing; energy consumption; joining; thermo crimping

Evaluation of energy measurements for error detection in press-fitting processes - Sand, Christian; Meiners, Moritz; Eberle, Jonathan; Franke, Jörg (2018 2nd International Symposium on Small-Scale Intelligent Manufacturing Systems, SIMS 2018, 2018)
Modern assembly lines consist of many different stations like assembly presses, which are rigidly chained or stand-alone on the shop floor. Current state-of-the-art process monitoring regards force-way curves to classify good or defective process runs using tolerance windows or envelop curves. Yet, approaches for online monitoring based on energy data are hardly used in assembly presses. Therefore, avoidable failure and scrap costs, as well as resource and material waste occur due to commonly unobserved malicious process states. This paper evaluates which types of errors can be detected and if an energy-based process observation is a useful addition or alternative to conventional process monitoring. Here, relevant information is used to generate deeper insight into assembly processes. Impacts like altered material, different batches of supply parts, tool wear and tool breakage shall be revealed by utilizing electrical current curves. Therefore, assembly settings are varied by six impact factors to evaluate their significance on force-displacement-curves. Eventually, a methodology on how to detect and compare key points in characteristic curves is proposed when evaluating energy data acquisition with current-displacement-curves thus presenting possible prospective research topics on deeper data analysis with data mining methods.
CRIS-Team Scopus Importer:2023-03-07
Keywords: current-displacement-curve; DoE; Force-displacement-curve; press-fit connection

Evaluation of energy measurements for error detection in press-fitting processes - Sand, Christian; Meiners, Moritz; Eberle, Jonathan; Franke, Jörg (Small-scale Intelligent Manufacturing Systems (SIMS), 2018 2nd International Symposium on, 2018)

Evaluation of Influences on Accuracy of Radiographic Measurements of Solder Joint Volume - Voigt, Christian; Hagag, Amr; Kirchberger, Manfred; Franke, Jörg (Proceedings of the International Spring Seminar on Electronics Technology, 2021)
Optimization of the pin in paste (PiP) printing process requires accurate and time-efficient evaluation of solder deposits for through-hole devices (THD). In an effort to identify a methodology that provides an optimized time-To-precision ratio for the evaluation of non-pinned, non-planar solder deposits this paper evaluates the state of coaxial single image X-ray evaluation of similar volumes using grayscale referencing as applied to post reflow deposits. It proposes a precise measurement approach utilizing laser scan microscopy as a reference and furthermore evaluates the significance of various influences on the accuracy and efficacy of coaxial X-ray measurements using planar material samples. The factors evaluated in this paper include the utilization of dynamic range, image distortion caused by cone-beam geometry and homogeneity of sample material for greyscale interpolation, and calculation of absorption coefficients by statistical analysis. The accuracy achieved using coaxial X-ray imaging and subsequent pixel-wise analysis of material thickness has proven difficult for geometrically complex volumes, though consideration of the proposed factors and subsequent optimization of the evaluation algorithm could potentially increase the viability of the method as a quick and flexible way of measuring complex volumes of material.
CRIS-Team Scopus Importer:2021-09-10

Evaluation of Influencing Factors on the Heavy Wire Bondability of Plasma Printed Copper Structures - Kästle, Christopher; Losch, Timo; Franke, Jörg (Proceedings of the 17th Electronics Packaging and Technology Conference (EPTC), 2015)
Power semiconductor devices and systems enable the efficient conversion and management of electrical energy. Power electronic applications range from fewer watts up to several mega- and gigawatts. Driven by a continuous electrification of society, power electronics are not only found in the automotive and energy sector, but also in industrial and lighting applications, as well as consumer electronics. In power electronic devices wire bonding is the established and predominant top-level interconnect technology due to a high process stability and low production costs. Characterized by a great process flexibility it might also be the predominant interconnection technology of coming additive manufactured devices and structures if wire bonding proves to be capable of connecting printed layers that form the basis of additive functionalized and even three-dimensional power device layouts. This paper will therefore display the influencing factors, as well as the possibilities and challenges that come along with the process combination of cold active atmospheric plasma printing with large wire aluminum bonding. For the investigations, copper layers are additively printed on Al2O3 ceramic substrates. Based on the printing parameters the most influential characteristics of the printed layers are derived. The influence and effectiveness of various steps of post processing such as grinding and cleaning are discussed. Last, a production series of 300 µm aluminum wires is bonded on the generated copper layers. The process stability as well as the interconnection quality is evaluated by destructive pull and shear tests and metallographic cross sections.

Evaluation of Laser-welded Electrical Steel Laminations for Electric Motors - Ziegler, Marco; Brandl, Florian; Kühl, Alexander; Franke, Jörg (12th International Symposium on Advanced Topics in Electrical Engineering, ATEE 2021, 2021)
The soft magnetic core is a basic component in electric motors, along with the winding and insulation systems. Soft magnetic cores are continuously magnetized and demagnetized to guide and amplify the magnetic flux. To reduce iron losses during operation, stator and rotor cores are usually made of thin laminated iron-silicon sheets insulated electrically from each other. These materials are easy to process (cutting, joining etc.), the costs are low, and the magnetic as well as the mechanical properties are adjustable during production. Due to the increasing requirements for electric motors for automotive sector, the material grades and corresponding manufacturing processes have been even optimized. For the production of Fe-Si laminations, the single sheets are stacked and joined. For this purpose, laser beam welding is increasingly used, especially in the series production of larger stators. However, the welding process affects the microstructure in the heat-affected zone and creates an electrically conductive connection between the single sheets. This increases the production-related iron losses, which have to be considered already in the design of the electric machine. As part of this research paper, the impact of laser welding of Fe-Si electrical steel sheets on the electromagnetic properties is analyzed and relationships are derived. This makes it possible to consider the production-related impact factors at an early stage.
CRIS-Team Scopus Importer:2021-06-11
Keywords: Electric drives production; Electrical steel laminations; Iron losses; Laser welding; Soft magnetic materials

Evaluation of Machine Learning for Quality Monitoring of Laser Welding Using the Example of the Contacting of Hairpin Windings - Mayr, Andreas; Lutz, Benjamin; Weigelt, Michael; Gläßel, Tobias; Kißkalt, Dominik; Masuch, Michael; Riedel, Andreas; Franke, Jörg (8th International Electric Drives Production Conference (EDPC), 2018)

Evaluation of Market Designs for Local Energy Markets to Support the Distribution Grid - Teske, Franz; Funk, Felix; Fehrle, Adrian; Franke, Jörg (2022 IEEE PES Transactive Energy Systems Conference, TESC 2022, 2022)
The transformation of the energy system leads to an increased demand for ancillary services (AS) in the distribution grid. It is expected that local coordination of AS can be solved more efficiently by local energy markets (LEMs) than by pure grid measures due to competition, heterogeneity, and differentiation. In this paper, an evaluation of the LEM design for the provision of AS is conducted based on a two-stage literature analysis. Therefore, this paper contributes to a taxonomy of the two components that is conceptually and empirically grounded. In the analysis, a high degree of similarity can be observed regarding market participants and AS. However, concerning the AS approach, LEMs can be divided into two classes: flexibility markets and capacity allocation markets, each of which has different applications.
CRIS-Team Scopus Importer:2022-11-25
Keywords: ancillary services; congestion management; grid constraint; market mechanism; transactive energy

Evaluation of Mechanical Stress on Electronic Assemblies during Thermoforming and Injection Molding for Conformable Electronics - Schirmer, Julian; Reichenberger, Marcus; Wimmer, Annette; Reichel, Herbert; Neermann, Simone; Franke, Jörg (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
The integration of SMT components is necessary to produce more complex assemblies within the framework of conformable electronics. During High-Pressure-Forming (HPF) and subsequent overmolding electronic components must withstand high amounts of stress. In this study 0402- as well as 0603-sized chip resistors were mounted on different common polymer substrates using conductive adhesive paste followed by electrical and mechanical evaluation. Prior to HPF electronic components were positioned in areas of different local deformation. After HPF the specimen were characterized by shear force testing and electrical resistance measurements. In a similar manner, electronic components were tested to assess the mechanical behavior during injection molding. To examine different melt induced stress scenarios, electronic components were arranged parallel as well as perpendicular to the flow direction of the melt at different positions. Additionally, three different injection speeds were evaluated to assess the influence on the electrical conductivity and functionality of the assemblies. It was found that meandering of conductors is necessary for higher deformations. El. components (without additional nonconductive adhesives) can be placed in areas of up to 15% deformation, smaller package sizes seem to be advantageous for HPF. Regarding overmoulding, it was found that larger components (larger bonding area) is beneficial. Also, placement near the injection point, as well as low injection speeds should be avoided. Overall, el. components should be protected (using globtops / underfills etc.) to withstand consecutive HPF and overmoulding.
CRIS-Team Scopus Importer:2021-03-26
Keywords: conductive adhesive.; conformable electronics; electric components; high-pressure-forming; In-Mold Electronics; injection molding; printed electronics; stress testing

Evaluation of monitoring approaches for the ultrasonic crimping process of tubular cable lugs - Seefried, Johannes; Gläßel, Tobias; Zürn, Marcel; Franke, Jörg (Proceedings of the 7th International Electric Drives Production Conference (EDPC), 2017)
Keywords: Temperature measurement; monitoring; crimping; welding; ultrasonic crimping

Evaluation of soft magnetic ferrosilicon FeSi6.5 for laser beam melting - Urban, Nikolaus; Bauch, Lukas; Armbruster, Rouven; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Evaluation of the Cold Atmospheric Plasma Metallization of Bare Dies with Copper Through Life Cycle Assessment - Ockel, Manuela; Funk, Felix; Janisch, Lucas; Franke, Jörg (Production at the Leading Edge of Technology. Proceedings of the 13th Congress of the German Academic Association for Production Technology (WGP), Freudenstadt, November 2023, 2024)
The cold atmospheric plasma metallization (CAPM) with copper is an alternative coating process to electroplating for applying a thermo-mechanical buffer onto bare dies to enable more powerful top-side interconnection technologies for power electronics. A complete life cycle assessment (LCA) is to be performed in order to evaluate improvements to increase sustainability of the copper metallization. Since life cycle assessment results strongly depends on the set system boundaries and availability of primary data, the scope of this study is determined by the availability of the latter. Since the coating properties are dependent on the plasma spray parameters, a variation of set parameters is assessed, which are currently used for the coating of the bare dies. The evaluation showed that electricity, plasma gas and powder production have major impacts on the sustainability. The necessary heat treatment is responsible for on third of the emissions if bare die production and plasma coating are included into the assessment. Potential improvements are the reduction of total conveyed powder and carrier gas, as well as increasing the number of bare dies treated in one annealing process.
CRIS-Team Scopus Importer:2023-12-15
Keywords: Cold Atmospheric Plasma Metallization; Copper; Life Cycle Assessment; Power Electronics

Evaluation of the coupling performance and long-term stability of aerosol jet printed and photolithographic manufactured waveguides for asymmetric optical bus couplers - Lorenz, Lukas; Ott, Lennard; Nieweglowski, Krzysztof; Reitberger, Thomas; Franke, Jörg; Bock, Karlheinz (Proceedings of SPIE - The International Society for Optical Engineering, 2019)
A novel coupling approach with specific coupling ratios depending on the coupling direction (optical bus to electrooptical device and vice versa) is presented. According to that, an asymmetric optical bus coupler (AOBC) is obtained, where a high amount of light is coupled from a device/module into the optical bus, whereas the ratio in the opposite direction is significantly smaller to keep enough energy in the bus for later coupling. This is realized without any filters by a specific bending of the waveguides. Hence, an up to four times higher coupling ratio in the module-to-bus direction is achieved compared to the opposite direction at the same junction. In contrast, current coupling schemes have a 1:1 coupling, waveguides are interrupted or filters are used. In this paper we investigate the influence of the waveguide manufacturing technology on the coupling performance. The standard photolithographic waveguides with rectangular cross-sections are compared to Aerosol Jet printed waveguides with circular segment cross-sections. Furthermore, we monitored the coupling for several days to get results on the stability. The results show a fluctuation of about ± 20 % for the printed waveguides and about ± 5 % for the photolithographic ones.
CRIS-Team Scopus Importer:2019-06-18
Keywords: Aerosol jet printing additive manufacturing; Asymmetric coupling; Interruption-free waveguide coupling; Multimode waveguide coupling; Optical bus coupler; Optics on surfaces; Photonic packaging

Evaluation of the influence of varying electrode materials within the thermo-crimping process - Spreng, Simon; Gläßel, Tobias; Hoetzel, Stefan; Schäfer, Heiko; Wunder, David; Franke, Jörg (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
In the field of electric drives manufacturing, the thermo-crimping process is one major technology to join insulated copper wires with belonging current carrying parts. However, due to its operating principle, this technology has to be associated with strong disadvantages e.g. the excessive tool attrition leading to an immoderate amount of maintenance operations. For this reason, this paper focuses on the investigation of varying crimping electrode materials, whereas the objectives product quality, tool attrition and process energy are analyzed.
CRIS-Team Scopus Importer:2023-03-07
Keywords: crimping tool; electric drives manufacturing; joining; thermo-crimping

Evaluation of the Sustainability of Decentralised Energy Systems for Domestic Applications - Teske, Franz; Fehrle, Adrian; Franke, Jörg (2020 IEEE Electric Power and Energy Conference, 2020)

Evaluation verschiedener Ansätze zur vollautomatisierten Montage von Weicheisenkernen auf Flachbaugruppen in traditionellen SMD-Linien - Voigt, Christian; Franke, Jörg (EBL 2020 - Elektronische Baugruppen und Leiterplatten, 2020)
Im Rahmen steigender Anforderungen an Auslastung, Kapazität und Automatisierung der Produktionsstätten elektronischer Baugruppen unterliegt die traditionelle Elektronikproduktionslinie bereits seit mehreren Dekaden enormen Optimierungsdruck. Teil dieses Prozesses ist auch die Reduktion des Anteils manueller Fertigungsschritte. Während bis zu 100.000 standardisierte SMD-Bauelemente pro Stunde durch hochautomatisierte Bestückautomaten auf Leiterplatten aufgebracht werden können, benötigen komplexe und großvolumige Bauteile häufig noch aufwendige manuelle Montageschritte. Zu diesen Bauteilen gehören Weicheisenkerne, welche in der Leistungselektronik für den Aufbau verschiedener induktiver Elemente benötigt werden. Während diese gegenwärtig selbst in hochautomatisierten Betrieben oft noch per Hand mittels zweier Metallklammern auf der Leiterplatte befestigt werden, bietet das typische Produktionsumfeld komplexer Elektronikbaugruppen eine Reihe theoretischer Möglichkeiten diese Montagemethode zu ersetzen. Hierzu wurden verschiedene Befestigungsmöglichkeiten untersucht: Die Verwendung von Klebstoffen, Befestigung mittels Schutzlackierung sowie die vollständige Montage zweier Kernteile durch einen SMD Bestückautomaten unter Einsatz einer Snap-Fit Verbindung. Letzteres wurde unter Anbetracht typischer Anlagencharakteristika im Rahmen einer Simulation auf die Durchführbarkeit hin untersucht. Alle weiteren genannten Optionen wurden, in ersten Testaufbauten mittels Scher-, Temperatur-, Schock- und Vibrationstests entsprechend DIN EN 61373 auf die Anwendbarkeit in einem Beispielaufbau evaluiert. Hierbei wurde einerseits festgestellt, dass es für diese Anwendung keine allgemeingültige Lösung zu geben scheint, anderseits, dass SnapFit und Klebstoffe mitunter großes Potential zur Fertigungsoptimierung bieten. <
Keywords: SMT; Induktion; Planarkern

Evaluierung der Rolle ungeplanter Ereignisse innerhalb verschiedener Produktionsstrategien - Bogner, Eva; Löwen, Ulrich; Franke, Jörg (Voraussschau und Technologieplanung, 2017)
Eine zentrale Herausforderung in der produzierenden Industrie ist der verbesserte und effiziente Umgang mit ungeplanten Ereignisse in der Produktion. Es gibt verschiedene ungeplante Ereignisse, wie beispielsweise Maschinenausfälle, denen bis zu einem gewissen Grad mit Technologien wie einer vorausschauenden Instandhaltung begegnet werden kann. Andere ungeplante Ereignisse hingegen erfordern maßgeblich eine schnelle und automatisierte Reaktion in Bezug auf die Produktionsplanung und -steuerung. Dazu zählen Eilaufträge, kurzfristige Änderungen von Lieferterminen oder Liefermengen. Jedoch spielen nicht in jeder Produktionsstrategie diese ungeplanten Ereignisse überhaupt eine Rolle und nicht jede Produktionsstrategie sieht überhaupt eine Reaktion auf diese vor. Daher gilt es bestehende Produktionsstrategien in Bezug auf solche ungeplanten Ereignisse zunächst einmal differenziert zu betrachten. Hierzu wird eine Kennzahl entwickelt, die eine objektive Bewertung von Auswirkungen eines ungeplanten Ereignisses und auch die Reaktionsfähigkeit einer Produktionsstrategie auf auftretende Abweichungen darlegt. Auf Basis der anhand der Bewertung als relevant erachteten Produktionsstrategien kann differenziert herausgestellt werden, welche Herausforderungen ungeplante Ereignisse mit sich bringen und welche Notwendigkeit in der Reaktion für die Produktionsstrategie entstehen.
Keywords: Industrie 4.0; Digitalisierung; Ungeplante Ereignisse; Produktionsstrategien

Examining Ag-Ag Direct Bonding on Chemically Coated DBC Substrates as a Pasteless Die-Attach Approach - Häußler, Felix; Schöttner, Jakob; Schubert, Johanna; Muckelbauer, Martin; Spiecker, Erdmann; Franke, Jörg (PCIM Europe digital days 2021; International Exhibition and Conference for Power Electronics, Intelligent Motion, Renewable Energy and Energy Management, 2021)
In this paper Ag-Ag direct bonding as a pasteless high temperature die-attach technology for power electronic applications on ceramic substrates is examined as conceivable alternative to silver sintering. To this end, sputtered Ag metallization on silicon chips and chemically coated direct bonded copper (DBC) substrates were bonded with varying parameters using design of experiments. Factors were pressure, bonding time and surface treatment. For the best parameter set average die-shear strengths of 29 MPa (out of 4 samples) have been reached processing non-polished silver coated DBC substrates at 250deg C with 20 MPa pressure and 60 minutes of process time. Microsections and images from a scanning acoustic microscopy (SAM) showed connected and non-connected areas at the joining interface. Lower shear strengths were found for polished surfaces than for the non-polished counterparts. By scanning electron microscopy (SEM) analysis the diffusion-based development of solid interconnection was confirmed, demonstrating feasibility of Ag-Ag direct bonding on grinded DBCs. The overall results affirm the viability and point out challenges of this die-attach proces
Keywords: silver direct-bonding; power electronics packaging

Examining the dynamics of bargaining power in buyer-supplier negotiations: insights from a case study in the German automotive industry - Bodendorf, Frank; Franke, Jörg (International Journal of Production Research, 2024)
Buyer-supplier negotiations play a central role in supply chain networks regulating the conditions for the exchange of goods. This paper investigates the relationships between influencing factors and their impact on bargaining power. In a multiple case study, we triangulate secondary data from 12 German automotive suppliers. Following a structural equation modelling approach, bargaining power and the effects of those influencing variables are analysed. Four relationships can be found. (1) The availability of internal resources and the existence of strong buyer-supplier relationships have a positive effect on bargaining power. (2) A positive influence of buyer-supplier relationships on gaining access to internal resources can be identified. (3) External market conditions have a small negative effect on bargaining power. (4) No significant effect can be found looking at the impact of external market conditions on internal resources or buyer-supplier relationships. The findings support theory by showing that internal resources and strong buyer-supplier relationships positively influence bargaining power. Based on these results, managers are advised to prioritise strategic resource allocation, implement win-win strategies, and employ benchmarking techniques to enhance competitiveness and strengthen bargaining positions.
CRIS-Team Scopus Importer:2024-01-26
Keywords: Bargaining power; buyer-supplier relationships; market conditions; negotiation; resources

Experimental determination of the suture behavior of aortic tissue in comparison to 3D printed silicone modelling material - Riedle, Hannah; Chaban, Ryan; Ghazy, Ahmed; Piplat, Charlotte; Dorweiler, Bernhard; Franke, Jörg (Journal of the Mechanical Behavior of Biomedical Materials, 2020)
The imitation of biological tissue in a synthetic physical model can benefit many medical applications, e.g. pre surgical planning or education. For a quantitative validation of the model's mechanical behavior, standardized testing on both, the biological original and the artificial material, is necessary. In four parts, this study focuses on the biomechanical analysis of the impact of sutures for aortic modelling using 3D printed silicone. Testing methods are developed and executed on biological and synthetic samples. The first part is the determination of the pullout strength of a single stitch. The second part is the investigation of the reduction of the tensile strength and elongation of tensile bars due to stitching. Third, the tensile testing of biological and artificial vessels repaired with an anastomosis gives information about the transferability to real surgical applications. A qualitative feedback study with surgical experts concludes the evaluation. The study reveals that the pullout strength is independent from the fiber or notch direction, but that repaired aortic tensile bars show a dependency on the fiber direction of the tissue. Additionally, the circular seam of the anastomosis provides a more stable connection than multiple single stitches. For the artificial models, the mechanical behavior mainly depends on the mechanical properties of the base silicone, here represented by the Shore A hardness, rather than the manufacturing process. When compared to the biological original the most similar material varies depending on the mechanical property in focus.
CRIS-Team Scopus Importer:2020-09-11
Keywords: 3D printing; Anatomical models; Aorta; Silicone; Suture

Experimental Evaluation of the Thermal Machine Tool Behavior for Model Updating. - Franke, Jörg; Maier, Tobias; Schäfer, Franziska; Zäh, Michael (International Journal of Automation Technology, 2012)

Experimental Evaluation of Tool Geometries for the Ultrasonic Crimping Process for Tubular Cable Lugs - Seefried, Johannes; Gläßel, Tobias; Kühl, Alexander; Mayr, Andreas; Franke, Jörg (2019 IEEE Holm Conference on Electrical Contacts, 2019)
In the production chain of electric drives, the electrical and mechanical contacting of the winding ends with a contact element is a time-consuming and cost-intensive process step. The most common processes, e.g., hot crimping, are characterized by high tool wear and enormous energy consumption. An innovative and at the same time energy- efficient process is the ultrasonic crimping process which also combines the two process steps of skinning and contacting in a single process. The thermal energy required for skinning is based on the damping of oscillation energy in the cable lugs used. Due to the direct heat generation in the cable lug and the oscillations coupled in, the process has high potentials with regard to process stability, contacting of high-frequency litz wires and energy consumption. However, some disadvantages like the occasional occurrence of fatigue fractures in the tubular cable lugs and unclear dependencies reducing process reliability have to be investigated. One possibility to avoid the cracks and to further increase the process stability of ultrasonic crimping is the evaluation of adapted tool geometries. In the context of this paper, different sonotrode and anvil geometries are compared and evaluated with regard to electrical, mechanical and visual connection quality.<br

Experimental identification and prioritization of design and process parameters on hole fill in mini wave soldering - Seidel, Reinhardt; Ahrens, Thomas; Friedrich, Jürgen; Reinhardt, Andreas; Franke, Jörg (Microelectronics Reliability, 2022)
Mini wave soldering is a common method for soldering through-hole components on printed circuit boards (PCB). With PCB design becoming increasingly complex and copper layer thickness rising, the vertical hole fill of through-hole solder joints becomes a serious problem during manufacturing. At the same time, the process window is limited by limited material heat resistance of the PCB and the through-hole components. Especially critical is latent damage inside the PCB and the through-hole component which must not exceed its specific maximum core temperature because this would compromise reliability over lifetime. The choice of soldering parameters is critical to reaching sufficient vertical fill to achieve a reliable connection according to IPC-A-610. The dedicated description of the interaction between PCB design and vertical fill has the potential to considerably improve the understanding of the basics of design for manufacturing (DfM). In this paper, the essential process parameters of the selective wave soldering process are examined by design of experiment (DoE) with respect to hole fill, which determines mechanical and thermal reliability as well as current carrying capacity. The results show the individual effects of the copper layer design parameters including layer count, layer thickness, hole copper plating attachment and solder alloy on vertical hole fill, in combination with the solder process parameters. The copper layer design parameters, solder bath temperature and preheating temperatures show the strongest effects. The soldering time has the lowest impact within the tested process parameters. For a given solder joint with its defined heat capacity, the benefit of solder time diminishes the longer the contact time is. Component surfaces and connector pin material and machine parameters like pump power as well as environmental conditions show little to no impact within a reasonable operation window.<br
Keywords: Selective wave soldering; THT component; Design of experiments; Hole fill

Experimental investigation and optimizationfor the effective parameters in the laser direct structuringprocess - Bachy, Bassim; Franke, Jörg (Journal of Laser Micro Nanoengineering, 2015)
The laser direct structuring (LDS) and the molded interconnect devices (MID) processes become more popular in the electronics industry. In order to produce micro MID products with highest circuit lines quality, it is very important to understand the complex relationship among the laser direct structuring parameters, the dimensions of the groove at the substrate surface, the profile of this groove, the width of the interactive zone (circuit line width) and space between two circuit lines (pitch). To reveal this relationship, experiments on the polymer plate (polyphthalamide PPA, with glass fiber) have been carried out in this work. It was found that the effect of the laser speed and laser power on the groove profile and dimensions are greater than the effect of the laser frequency, moreover the metallization profile depends on the groove profile which again depends on the LDS parameters. The dimensions of the resolidification groove edge including the width and height must be reduced to lowest possible value, in order to reduce the metallization defects.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Laser direct structuring process; Laser process; Microstructure; Molded interconnected devices process

Experimental Investigation of a Friction Ventilator - Renz, Andreas; Praß, Julian; Weber, Johannes; Becker, Stefan (Advanced Engineering Forum, 2016)

Experimental Investigation of a New Manufacturing Technology for Hairpin Stators with Litz Wires - Riedel, Andreas; Kühl, Alexander; Franke, Jörg; Graf, Rolf; Hubert, Thomas; Bauer, David (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
The increasing demand of electric drives in the mobility sector leads to continuous innovations in the development and production of electric machines. Currently, it can be seen that hairpin technology is well established in the automotive industry for traction drives. In addition to the high level of automation of the process, the reasons therefore are the achievable copper filling factors, which result from the flat conductors used and thus increase the power density of the electrical machine. However, at higher frequencies, as a result of higher driving speeds, large conductor dimensions, especially the height of the conductor, lead to undesirable aspects in the form of eddy current losses. These negative effects can be reduced by replacing the solid rectangular conductor with a stranded conductor. Therefore, the substitution of the conductor material in the field of hairpin technology can be classified as the next innovation stage. The base material is a twisted stranded conductor compacted into a rectangular shape. In this paper, a novel process chain for the manufacturing of a stranded hairpin stator is presented, individual process steps are analyzed and potential improvement measures are explained. Subsequently, an evaluation is made on the basis of an assembled and electrotechnically measured stator with stranded hairpins.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric traction drives; hairpin winding; litz-wire; stator manufacturing; stranded conductors; wire materials

Experimental Investigation on Thermocouple Attachment Methods for Reliable Temperature Measurement - Seidel, Reinhardt; Volland, Jana; Thielen, Nils; Voigt, Christian; Franke, Jörg (ISSE 2020, 2020)
Keywords: Temperature Measurement Reliability; Thermocouples; Design of Experiments; Soldering oven profiling

Experimental investigations of the needle winding technology regarding the influence of the wire guide geometry on the tensile wire force - Stenzel, P.; Dollinger, P.; Richnow, J.; Franke, Jörg; Endisch, C.; et al. (Proceedings of the IEEE International Conference on Industrial Technology, 2015)
The needle winding technology is distinguished by a high degree of flexibility and automation. However, high wire tension due to the tensile winding force proves to be detrimental. Wire stress can cause an increase of the ohmic winding resistance, thus leading to a decrease of the degree of efficiency and a reduction of the continuous power of an electric machine. A closed-loop-control of the tensile winding force is basically possible, however, the influence of the wire guide on the tensile force cannot be included due to the possible measuring positions. In order to use the automation potential of the needle winding technology it has to be ensured that quality and power of the winding products are not degraded. Therefore the influence of the tensile winding force on ohmic resistance as well as the influence of the geometry of the wire guide on the tensile force has to be known. However, such investigations have either not been conducted so far or are currently not publicly accessible. The winding parameters are usually based on experience, which is not sufficient for high power density applications. Therefore, in this paper experimental investigations are presented concerning the above mentioned topics and potentials for improvement are identified.
CRIS-Team Scopus Importer:2023-03-07

Experimental Mechanical Examination of Artificial 3D Printed and Post Processed Vascular Silicone Models * - Riedle, Hannah; Braunias, Kim; Mukai, Barbara; Franke, Jörg (2019 41st Annual International Conference of the IEEE Engineering in Medicine and Biology Society (EMBC), 2019)

Experimental Setup of a Process Chain for Contacting Litz Wires for Electrical Drives - Riedel, Andreas; Seefried, Johannes; Schmidt, Alexander; Kühl, Alexander; Franke, Jörg (30th International Conference on Electrical Contacts, ICEC 2020 - Proceedings, 2021)
The main objective in the development of electric drives is the continuous effort to increase the performance. One possibility to achieve this is the use of shaped litz wires. However, shaped litz wires present major challenges regarding the contacting process. In the preparation of the contacting process, the individual conductors of the litz wires must be completely stripped without residues and brought into a defined geometry. This preliminary process step is also known as compacting. The compacting process is the basis for the subsequent contacting of the litz wires with each other or with contact elements. One process for contacting the litz wires is laser beam welding. In the context of this publication, the process chain consisting of ultrasonic compacting and laser beam welding is evaluated. The focus is put on the possible variations of the litz wire topologies, which differ in single wire diameter, number of wires and degree of insulation. Depending on this, parameters for the two processes are elaborated. To evaluate the results, electrical and mechanical testing of the litz wire connections is carried out. In addition, different approaches for the qualification of the compaction quality, in particular the evaluation of insulation residues, are considered.
CRIS-Team Scopus Importer:2023-03-07

Explicit dynamics process simulation of linear coil winding for electric drives production - Bönig, Jochen; Bickel, Benjamin; Spahr, Michael; Fischer, Christian; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014, 2014)
Slowly but steadily, more and more electric vehicles push onto the consumer market. For a cost efficient production of electrical engines, in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby the prediction of the wire behavior is one of the key challenges. Therefore, a detailed model is built to investigate wire behavior during the linear winding process. The finite element based simulation tool LS-DYNA serves as explicit dynamics tool. To represent the high dynamic process of winding within this simulation, some first adaptions have to be made. This means, that dynamic influences such as rotational speed or acceleration of the coil body are definable. Within process simulation, the given boundary conditions are applied to the model. The material properties of the wire under scrutiny are validated by a tensile test and by the values out of datasheets in previous research. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behavior. Furthermore, specific adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers adequate process parameters and, thus, expertise in winding technology. Nevertheless, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of winding process, in which varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in this field. The generated model enables the user not only to influence the process parameters but also to modify the geometry of a winding body. To make the simulation scientifically sound, it is validated by previous experiments and simulations
Keywords: coil winding; Explicit dynamics; simulation

Explicit FEM analysis of a new contacting method for electronic devices with novel wiring harnesses - Spahr, Michael; Bönig, Jochen; Gläßel, Tobias; Spreng, Simon; Ebert, T.; Franke, Jörg (61st IEEE Holm Conference on Electrical Contacts, HOLM 2015, 2015)
Through customers' desire for an individualization of vehicles, new electronics-supported functions are continuously being added. The automobile wiring harness must meet these requests without any further increase of weight and volume. The basic trend towards a modular vehicular design, the continually growing complexity of production and assembly processes, supports the use of flexible flat cables (FFCs) in a hybrid wiring system architecture. For an integral approach, it is also important to develop corresponding alternatives for electrically contacting FFCs with the components. To that end, the process-conditional, one-sided accessibility of FFCs represents a particular challenge. Motivated by these challenges, the Institute FAPS has developed an automated assembly system of FFCs and a new concept for a flexible electric contacting system enabling direct electrical contacting of installed FFCs. The scope of this approach is the analysis of the new contacting method by means of an explicit finite element analysis (FEA). For this purpose, a numerical model was developed that enables the simulation and optimization of the contacting process and its important parameters. In a second step, the results of the FEA are validated by respective experiments.
Keywords: contact area; contact force; contact resistance; electrical contact; finite element modelling; flexible flat cable

Explicit finite element analysis for rotary cutting of electrical steel sheet - Hubert, Markus; Weigelt, Michael; Spahr, Michael; Franke, Jörg; Hackert, Jürgen; Mehlhorn, Marcus (6th International Annual Engineering Seminar, InAES 2016, 2017)
Rotary cutting of rotor and stator laminations complements the available methods in the processing of electrical steel sheet. Furthermore, with this process, a technological answer to the production of ever-Thinner laminations can be found in which high-speed stamping is reaching its technical limits. This paper explicates a finite element analysis for the rotary cutting process of electrical steel. First an overview of the cutting process and its peculiarities is given. Then the setup for the FEM simulation and its material model are explained. Finally followed by a discussion of simulation results with different parameters.
Keywords: electric steel processing; finite element analysis; rotary cutting

Fabrication of metal-ceramic substrates by laser powder bed fusion using a high-power green laser and high temperature preheating - Hecht, Christoph; Ockel, Manuela; Stoll, Thomas; Franke, Jörg (Proceedings Volume 12876, Laser 3D Manufacturing XI, 2024)

Fahrplan in die Zukunft - Six Sigma weitergedacht für Business Excellence - Berg, Stefan; Köhler, Markus; Kurz, Gerhard; Schäfer, Franziska; Schwulera, Erik (QZ Qualität und Zuverlässigkeit, 2020)
Damit Unternehmen auch in einem immer komplexeren Umfeld nach wie vor Wettbewerbsvorteile generieren, müssen sich auch Six Sigma und Business Excellence weiterentwickeln. Die wichtigsten Handlungsfelder und ihre Zusammenhänge hat der European Six Sigma Club Deutschland e. V. identifiziert und in einer Roadmap zusammengefasst. Unter anderem eröffnet diese auch neue Perspektiven für die Rollen der Six Sigma Belts. Dies zeigte sich auch in der Praxis bei der Darstellung der Handlungsfelder bei zwei Industrieunternehmen
Keywords: Six Sigma; Business Excellence

Failure dependent progression of contact resistance in thermal-shock testing of spring-clip contacts - Friedlein, Matthias; Spahr, Michael; Süß-Wolf, Robert; Franke, Jörg (2017 IEEE Holm Conference 2017, 2017)
Through ever changing terms and regulations on fuel consumption and emissions, weight becomes the number one concern of car manufacturers. Meeting those new regulations and the customer's desire for more options and variations is only possible without adding more weight by changing the wiring harnesses' technology. One solution to face this problem can be found by the application of flexible flat cables (FFCs) instead of common round cable wire systems. For a holistic approach, it is important not only to establish automated ways of cable installation, but also methods of automatically contacting components. Therefore, a new direct contacting method was developed at the Institute for Factory Automation and Production Systems (FAPS). The innovative contacting method enables to contact an automatically mounted one side accessible FFC with kinematic systems of industrial robots in an automated way. However, before new technologies can be applied to serial production, car manufacturers demand standardized climatic tests. In this paper, a correlation was discovered between the progression of contact resistance and failure mechanisms during thermal shock testing. Furthermore, an influence of different peak temperatures and materials was identified and the results were verified via SEM micrographs.
Keywords: thermal-shock testing; automotive wire harness; reliability; contact resistance; degradation mechanisms

FAPS – Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik - Brandmeier, Markus Andreas; Bogner, Eva; Franke, Jörg (Industrie 4.0 Management : Gegenwart und Zukunft industrieller Geschäftsprozesse, 2016)
Im Kontext der vierten industriellen Revolution wird maßgeblich von einer zunehmenden Flexibilisierung und Individualisierung gesprochen. Der Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik kreiert und realisiert dafür Innovationen durch die Integration von Wissen aus unterschiedlichen Domänen und Fachbereichen der Produktion und gesamten Wertschöpfungskette. Das übergreifende Forschungsziel liegt in der Vernetzung aller Teilfunktionen einer Fabrik zu einem rechnerintegrierten Gesamtkonzept. Durch die Vielzahl der Kooperationen mit wissenschaftlichen Einrichtungen und industriellen Betrieben findet neben intensiver Forschung auch ein stetiger Technologieaustausch mit der Industrie statt. Sowohl langfristige Forschungsprojekte als auch kurzfristige Dienstleistungen werden in enger Zusammenarbeit mit den Partnern in den sechs Forschungsbereichen Elektronikproduktion, Elektromaschinenbau, Bordnetze, Biomechatronik, System Engineering und dem E|Home-Center bearbeitet.
Keywords: digitalization; condition monitoring; smart logistics; big data; integrated engineering

Fault detection for autonomous multirotors using a redundant flight control architecture - Lieret, Markus; Fertsch, Jonas; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2020)
Within the last years unmanned aerial vehicles (UAV) have found their way into several industrial applications and are currently considered to be a highly efficient solution to deliver parcels to end costumers. However, a power shutdown or emergency stop of the propulsion system in the case of a failure is compared to stationary or mobile ground robots no suitable reaction as it leads to a fall of the UAV and hence creates a safety hazard for persons in the surroundings. Thus it must be ensured that the UAV is not only capable of detecting occurring failures but also of remaining airworthy and navigable at any time.Within this work we therefore present a fault detection approach for autonomous multirotor systems using a redundant flight control architecture. The presented fault detection methodology is capable of analysing flight control units (FCU) based on different hard-and software and does not require a precise time synchronization. To deal with different and unsynchronized FCUs we design and implement an inexact voter to continuously compare states and functionalities of the individual FCUs. In the case of a failure or break down of the active FCU the developed architecture has the ability of switching to one of the fallback systems.The approach and algorithms used for failure detection are presented in detail and afterwards the overall system is evaluated using a hexarotor in different flight states and conditions.
CRIS-Team Scopus Importer:2020-11-06

Feasability study of piezo jet printed silver ink structures for interconnection and condition monitoring of power electronics components - Müller, Martin; Franke, Jörg (2017 IEEE 19th Electronics Packaging Technology Conference, EPTC 2017, 2018)
In the field of power electronics, assembly and interconnection technologies play an important role for the design of modules and systems. The applied packaging technologies largely determine the electrical, thermal and mechanical properties of the final module. In addition to conventional solder technology upcoming technologies like sintering, transient liquid phase soldering, adhesive bonding or even reactive multilayer materials are interesting methods for the realization of the die attach. [1] This paper is about a combination of sintering and adhesive bonding for the interconnection of power electronics components. As interconnection material a highly viscous conductive silver ink is used. Additionally also sensor structures were printed with the same silver ink to test the potentials for condition monitoring applications in the field of power electronics.
CRIS-Team Scopus Importer:2023-03-07

Feasibility Investigations on Selective Laser Melting for the Development of Microchannel Cooling in Power Electronics - Syed Khaja, Aarief Hussain; Perinan Freire, Antonio; Kästle, Christopher; Franke, Jörg (Proceedings of the 67th Electronic Components and Technology Conference (ECTC), 2017)
The introduction of new generation semiconductor materials into power electronics brings not only performance improvements but also technological challenges for the thermal management as the urge for high temperature operating power modules and packaging systems increases. The limiting factor for the performance and application range is not anymore the chip temperatures but the restrictions of the state-of-the-art packaging systems. Especially for high power applications, the temperatures can rise to more than 200 °C at the interconnect level. In this paper, as a contribution towards the above requirements, the selective laser melting (SLM) technique has been used to fabricate a heat sink concept which would not be feasible with conventional production techniques. Here the feasibility of producing a heat sink concept with SLM based on micro-cooling technology is successfully introduced and the thermal management performance is demonstrated. The advantages mainly for the volume and weight reduction along with performance improvement are highlighted.

Feasibility Studies on Selective Laser Melting of Copper Powders for the Development of High-temperature Circuit Carriers - Syed Khaja, Aarief Hussain; Kästle, Christopher; Franke, Jörg (Proceedings of the 49th International Symposium on Microelectronics, 2016)
The introduction of new generation semiconductor materials into power electronics brings not only performance improvements but also technological challenges for the thermal management as the urge for high temperature operating power modules and packaging systems increases. The limiting factor for the performance and application range is not anymore the chip temperatures but the restrictions of the state-of-the-art packaging systems. Especially for high power applications, the temperatures can rise to more than 200 °C at the interconnect level. In this paper, as a contribution towards the above requirements, the selective laser melting (SLM) technique has been used to fabricate a heat sink concept which would not be feasible with conventional production techniques. Here the feasibility of producing a heat sink concept with SLM based on micro-cooling technology is successfully introduced and the thermal management performance is demonstrated. The advantages mainly for the volume and weight reduction along with performance improvement are highlighted.

Feasibility study of generating mechatronic devices by digital direct metallization with a plasma based copper coating process - Müller, Martin; Franke, Jörg (Proceedings of the International Spring Seminar on Electronics Technology, 2016)
Digital Direct Metallization (DDM) is an innovative process for the production of planar or three dimensional circuit carriers. Both conductor lines for logic circuits and conductors for high power transmissions can be realized. This paper describes the manufacturing process chain of Digital Direct Metallization by plasma based copper coating and shows the potentials of this technology. Circuits can be applied to almost any base substrate such as polymers, ceramics or even metal since an insulating dielectric lacquer layer separates the substrate from the metallization. In contrast to previous plasma based copper depositing processes the Digital Direct Metallization enables clearly defined fine structures without using any inflexible and high-maintenance masks [1]. An enormous advantage of this procedure is the complete elimination of wet chemical process steps, which are known from the laser direct structuring method (LDS) [2]. In addition to diverse mechanical and electrical characterizations this paper represents the opportunities of the technology by means of a demonstrator application.
CRIS-Team Scopus Importer:2023-03-07

Fehlerklassifikation auf Röntgenbildbasis - Wilke, Peter; Feldmann, Klaus; Götz, Knuth (Tagungsband Symposium Anwendung von Fuzzy-Technologien und Neuronalen Netzen, 1996)

Feldlabor der Energiewende - SWW Wunsiedel GmbH und E|Home-Center arbeiten Hand in Hand an der Umsetzung des Wunsiedler Wegs Energie 2.0 - Bürner, Johannes; Böhm, Ralf (Umwelt-Technologie und Energie in Bayern, 2015)

Fertigungsbegleitende Qualitätskontrolle in der Elektromotorenfertigung - Meyer, Alexander Wilhelm; Abersfelder, Sandra; Urban, Nikolaus; Schneider, Michael; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2017)
Keywords: E|DRIVE

Finite‑element‑analysis of the mechanical behavior of high‑frequency litz wire in flat coil winding - Weigelt, Michael; Thoma, Cornelius; Zheng, Erdong; Franke, Jörg (Production Engineering, 2020)
Numerous applications of daily life use flat coils, e.g. in the automotive area, in solar technology and in modern kitchens. One common property that all these applications share, is a flat coil made of high-frequency (HF) litz wires. The coil layout and the properties of the HF litz wire influence the winding process and the efficiency of the application. As a result, the HF litz wire must meet the complex technical requirements of the winding process and of the preferred mechanical, electromagnetic and thermal properties of the HF litz wire itself. Therefore, a reasonable configuration and optimization of HF litz wire has been developed with the help of a finite-element-analysis (FEA). In this work, it is first shown that the mechanical behavior of HF litz wire under tensile and bending stress can be simulated. Since the computational effort for modelling an HF litz wire at the single conductor level is hardly manageable, a suitable modelling strategy is developed and applied using geometric analogous models (GAM). By using such a model, HF litz wires can be designed for the specific application and their behavior in a winding process can be predicted.
Keywords: High frequency litz wire; Flat coil winding process; Inductive power transfer system; Finite element analysis; LS-DYNA

Flexibilization of Biogas Plants through Intelligent Automation Generates Earning Opportunities - Spanheimer, Robert; Franke, Jörg; Erdmann, Diana-Maria; Schaidhauf, Ralph M.; Böhm, Ralf (Advanced Engineering Forum Vol. 19, 2016)
Due to guaranteed feed-in tariffs under the Renewable Energy Act and the feed-in precedence of renewable power generation plants the operation of biogas plants in Germany is currently plannable and economically advantageous. However, it is foreseeable that without this subvention biogas plants cannot compete with other regenerative plants such as photovoltaic and wind power plants on the open electricity market. Accordingly, it is of great importance for biogas plant operators to identify and occupy suitable niches to make full use of the unique features of their plants. Because of their predictable availability, those plants can particularly benefit of earning opportunities in times of high demand and contribute to grid stabilization. In order to keep the effort for plant operators as low as possible the automation of existing biogas plants can be extended and enabled to communicate with market platforms or control centers of the distribution system operator. Thus biogas plants can contribute to balancing group compensation not only for accounting purposes but factual by appropriate feed-in into the electrical network in consideration of actual demand.
Keywords: Biogas Plants; Digitalization; Direct Marketing; Energy Flexibility; Feed-In Tariffs

Flexible automation for the production of contactless power transfer systems for electric vehicles - Risch, Florian; Günther, Stefan; Bickel, Benjamin; Franke, Jörg (2013 3rd International Electric Drives Production Conference, EDPC 2013 - Proceedings, 2013)
The increasing electrification of the automotive power train leads to significant changes in automotive value chains, while sales potentials are still uncertain [1]. Due to their considerable advantages in regard to safety and convenience, contactless power transfer systems may be the basis for further increasing the customers' acceptance for electrified vehicle concepts [2]. Increasing market acceptance will require high volume production concepts for contactless power transfer systems. Thus, the importance of automated assembly and manufacturing technologies moves into the focus. Especially the winding process of the HF-litz wire coil structures shows potential for further rationalization. Therefore, it is the aim of this paper to present flexible automation concepts for this process. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: contactless power transfer systems; electric vehicles; flexible production concepts; winding of HF-litz wires

Flexible automation for the production of stators and rotors of electric vehicles - Risch, Florian; Tremel, Jan; Klier, Tobias; Franke, Jörg (Advanced Materials Research, 2014)
The increasing electrification of the drive train will-sooner or later-lead to significant changes in the value chains for vehicle manufacturers and suppliers, while sales potentials are still uncertain. Due to the currently small number and high diversity of industrial electric motors with higher power and the complex handling of the necessary materials, the processes are based on manual labor content. For the automotive industry high volume production concepts for electric traction motors will be required in the future. Thus, the importance of automated assembly and manufacturing technologies for electric motors moves into focus. In the production of electric motors e.g. the wiring processes of the stators and the magnet assemblies for permanent-magnet synchronous rotors show potential for further process rationalization. This paper presents alternative approaches for the automation of wiring and magnet assembly processes developed at the Institute for Factory Automation and Production Systems (FAPS) at the Friedrich-Alexander-University of Erlangen-Nuremberg. © (2014) Trans Tech Publications, Switzerland.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Coil winding; Electric drive systems; Electric mobility; Permanent magnet assembly; Production technologies; Robotic assembly

Flexible Automation in High-Variant Electronics Production through Digital Planning of Advanced Hybrid Robot Systems - Metzner, Maximilian; Albrecht, Felix; Handwerker, Andreas (European Robotics Forum 2019 (ERF2019), 2019)

Flexible Automatisierung der Statorenmontage mit Hilfe einer universellen ambidexteren Kinematik: Dissertation - Kühl, Alexander (Meisenbach, 2014)
Die fortgeschrittene Globalisierung stellt auch die Branche des Elektromaschinenbaus vor die große Herausforderung, in einem Land mit hohem Einkommensniveau global wettbewerbsfähig zu produzieren. Um die Wertschöpfung nachhaltig im Land halten zu können, ist für die Hersteller elektrischer Antriebe die Entwicklung kundenorientierter Produkte sowie effizienter und innovativer Montageprozesse entscheidend. Ziel der vorliegenden Arbeit war daher die Konzeption dieser Prozesse unter dem Fokus der Flexibilität der Produktionsmittel. Die Montage von Wicklungen und Deckschiebern mit Hilfe einer dualarm- Roboterkinematik, die Einordnung des entwickelten Montagesystems sowie die Konzeption der übrigen Prozessschritte bildeten die Schwerpunkte. Bestehende Montagesysteme zur Produktion elektrischer Antriebe zeichnen sich entweder durch eine sehr starre Automatisierung oder viele manuelle Tätigkeiten aus. Da Vorrichtungen automatisierter Linien auf bestimmte Statortypen ausgelegt und trotz der fehlenden Flexibilität sehr kostenintensiv sind, ist die Weiterverwendung manueller Hilfsmittel für robotergestützte Montagezellen deutlich zielführender umzusetzen. Die gegenüber einer menschlichen Arbeitskraft dem Roboter fehlenden Sinne und kognitiven Fähigkeiten erfordern jedoch eine Anpassung an den Einsatz dieser Hilfsmittel. In diesem Zusammenhang erfolgte im Rahmen der Arbeit zunächst die Konzeption einer Wickelschablone die ohne Kollisionsgefahr von einem Roboter angefahren werden kann. Die entwickelte Drei- Kammern-Schablone stellt eine kostengünstige, zugängliche und schnell zu rüstende Alternative zu universellen Wickelschablonen dar. Nach Erweiterungen besteht ebenfalls die Möglichkeit, die Positionen der Drahtenden festzulegen und damit definiert zu übergeben. Auch bisherige Lösungen, in der Zelle einen Stator definiert zu spannen, erweisen sich als ungeeignet für eine robotergestützte Montage. Beim Spannen des Blechpakets in eine Vorrichtung, die den Stator während des manuellen Einziehens fixiert, ist es nur mit einem hohen Zeitaufwand möglich, den Stator konzentrisch einzulegen. Die einzelnen Spannzangen wurden daher durch einen Kniehebel ersetzt. Dieser ermöglicht das schnelle Spannen mit definierter Mittelachse und Bezugsebene. Die Flexibilität gegenüber verschiedener Statordurchmesser wird durch kostengünstige, schnell zu rüstende, austauschbare Schalen gewährleistet. Nach der automatisierungsgerechten Vorbereitung der Montagezelle war es möglich, die Prozesskette zur flexiblen Montage von Statoren zu konzeptionieren. Ausgehend von einem nutgrundisolierten Stator ist der erste Prozessschritt die Montage der Wicklung. Die beschädigungsfreie Handhabung der biegeschlaffen Drähte ist hierbei eine der wesentlichen Herausforderungen. Um diese zu realisieren, wurden verschiedene Konzepte erstellt, bewertet und aufgebaut. Bei diesen nimmt der eine Roboterarm die Wicklung aus der definierten Lage in der Schablone der Wickelmaschine auf und positioniert sie in der Statornut. Der zweite Roboterarm unterstützt diesen Einziehvorgang, durch die Handhabung des Gegenwerkzeuges. Beide Konzepte unterscheiden sich in der Anzahl der übertragbaren Spulen. Während der elektromechanische Greifer des ersten Prototypens dafür ausgelegt wurde, Einzelspulen möglichst flexibel einzulegen, werden beim Prototypen des zweiten Konzeptes Spulengruppen mit Hilfe eines Einziehwerkzeuges in den Stator gezogen. Neben der Verkürzung der Prozesszeit ist hierbei v.a. der Kontaktierprozess wesentlich effektiver durchzuführen. Nach der Montage müssen die Wicklungen fixiert und isoliert werden. Bei Versuchen mit ersten Prototypen wurde klar, dass die robotergestützte Montage vormagazinierter Deckschieber v.a. aufgrund der biegeschlaffen Wicklungen innerhalb und außerhalb des Stators nur sehr schwierig zu realisieren ist. Neben den Problemen mit der Zugänglichkeit stellte sich v.a. das Einfädeln und Einschieben des Materials als problematisch dar. Mit der Weiterentwicklung zu einem zweiten Prototyp, welcher Transport, Formgebung, Zuschnitt, Zuführung und Einschieben der Deckschieber aus dem Lieferzustand des Isolierbandes übernimmt, können die Probleme der Zugänglichkeit und des Materialtransportes überwunden werden. Ein drittes Werkzeug umgeht die genannten Probleme durch eine Substitution des Prozesses. Nach ausführlicher Materialrecherche und Auswahl konnte an Stelle des seitlichen Einschiebens eines festen Stoffes ein geeigneter Kleber von oben in die Nut appliziert und mittels UV-Licht ausgehärtet werden. Das System ist flexibel gegenüber des Statortyp, sowie der Anzahl der zu produzierenden Motoren und ermöglicht zudem die Erweiterung um den Prozessschritt der Nutimprägnierung. Für die künftige Weiterentwicklung der Deckschieber-Technologie ist neben der Untersuchung von Prozess- und Materialalternativen auch eine verbundene, detaillierte Analyse der Lebensdauer der Wicklung zielführend. Neben mechanischen, thermischen und elektrischen Einflüssen können hier auch Funktionsmaterialien berücksichtigt werden. Zur Schließung der Prozesskette wurden die folgenden Schritte Kontaktierung und Wickelkopfformen konzeptioniert. Die vorgestellten Werkzeuge ermöglichen das schaltrichtige Einsammeln der freien Wicklungsenden sowie die Zuführung zu einer Heißcrimpanlage. Die Integration des Kontaktierprozesses in ein robotergeführtes Werkzeug ist aufgrund der spezifischen Prozessparameter, der hohen Ströme und Spannungen nur bedingt sinnvoll. Ebenfalls nicht ohne zusätzliche Werkzeuge und Aktoren kommt das Wickelkopfformen aus. Aufgrund der hohen Prozesskräfte übernimmt der Roboter lediglich die Handhabung der Werkzeuge. Die Prozesskräfte werden über einen linearen Pneumatikaktor auf ein Werkzeug übertragen, welches durch seinen komplexen geometrischen Aufbau diese nutzt, um die Wicklung axial und radial zu komprimieren. Die vorgestellten Prozesse wurden zu einem Montagesystem projektiert. Im Fokus stand hierbei, Prozesse - wenn möglich - zu parallelisieren und nur - wenn nötig - mit einer Kooperation der beiden Roboterarme abzuarbeiten. Das System wurde im Rahmen der Arbeit simulativ untersucht. Neben der Offline-Programmierung stand hierbei v.a. die Systemoptimierung durch eine Ablaufsimulation im Vordergrund. Es wurden kritische Prozessschritte, wie die zeitintensive Montage der Deckschieber durch einen Roboterarm, detektiert und Maßnahmen, wie die Erweiterung um eine zweite Wickel- und Roboteranlage vorgeschlagen, die zu einer Effizienzsteigerung des Systems führen. Die Analyse der Wirtschaftlichkeit und der Prozesszeiten sowie der qualitative Vergleich der Prozessschritte validiert die Zelle mit einem resultierenden Einsatzszenario. Hierbei kann nachgewiesen werden, dass ein flexibel robotergestütztes Montagesystem, wie in dieser Arbeit konzeptioniert, bei einer jährlichen Produktion in mittleren Stückzahlen wirtschaftlicher arbeitet als eine manuelle oder vollautomatisierte Linie. Innerhalb der vorliegenden Arbeit wurden Technologien, Prozesse und Systeme aufgezeigt, die eine effiziente und flexible Montage von Elektromotorstatoren ermöglichen. Für eine Umsetzung in einer industriellen Umgebung müssen jedoch einerseits die konzeptionierten Werkzeuge weiterentwickelt, andererseits auch die Technologien unternehmensexterner Partner (Kontaktierung) flexibler gestaltet werden. Eine wichtige Voraussetzung für die Industrialisierung der Prozesse im nächsten Schritt ist die steuerungsseitige Weiterentwicklung und der Einsatz von CAD/CAM-Ketten über die gesamte Prozesskette. Nach Erfüllung aller Rahmenbedingungen sind die Potentiale, wie eine schnelle Programmierung der Anlage und der Werkzeuge sowie Rückschlüsse auf die montagegerechte Konstruktion von Statoren, enorm. Ebenfalls wichtig ist die Optimierung moderner Sensoriksysteme. Eine prozesssichere Detektion von Objekten mit kleinen geometrischen Abmessungen ermöglicht durch eine CAD/CAM-Kopplung neben der Korrektur von Montagefehlern auch das Greifen von freien Spulen- oder Wicklungsenden. Nach einer erfolgreichen Einführung und Umsetzung der robotergestützten Prozesse als Alternative zur manuellen oder automatisierten Prozesskette eröffnen sich für den Produzenten elektrischer Antriebe deutliche Potentiale zur Steigerung der Produktionsflexibilität und -effizienz.

Flexible Automatisierung in der Elektronikmontage mithilfe von MRK-Systemen - Metzner, Maximilian (Handbuch Mensch-Roboter-Kollaboration, 2019)
Keywords: Mensch-Roboter-Kollaboration; Elektronikproduktion; Robotik

Flexural Fatigue Test—A Proposed Method to Characterize the Lifetime of Conductor Tracks on Polymeric Substrates - Petillon, Simon; Knöller, Andrea; Bräuer, Philipp; Helm, David; Grözinger, Tobias; Weser, Sascha; Eberhardt, Wolfgang; Franke, Jörg; Zimmermann, André (Journal of Manufacturing and Materials Processing, 2022)
High quality and long product life are two fundamental requirements for all circuit carriers, including molded interconnect devices (MID), to find application in various fields, such as automotive, sensor technology, medical technology, and communication technology. When developing a MID for a certain application, not only the design, but also the choice of material as well as the process parameters need to be carefully considered. A well-established method to evaluate the lifetime of such MID, respective of their conductor tracks, is the thermal shock test, which induces thermomechanical stresses upon cycling. Even though this method has numerous advantages, one major disadvantage is its long testing time, which impedes rapid developments. Addressing this disadvantage, this study focuses on the laser direct structuring of thermoplastic LCP Vectra E840i LDS substrates and the subsequent electroless metallization of the commonly used layer system Cu/Ni/Au to force differences in the conductor tracks’ structure and composition. Performing standardized thermal shock tests alongside with flexural fatigue tests, using a customized setup, allows comparison of both methods. Moreover, corresponding thermomechanical simulations provide a direct correlation. The flexural fatigue tests induce equivalent or even higher mechanical stresses at a much higher cycling rate, thus drastically shorten the testing time.
CRIS-Team Scopus Importer:2022-04-29
Keywords: conductor track; flexural fatigue test; laser direct structuring; metallization; molded interconnect device

ForeSight-AI-based Smart Living Platform Approach - Bauer, Jochen; Hechtel, Michael; Konrad, Christoph; Holzwarth, Martin; Mayr, Andreas; Schneider, Sven; Franke, Jörg; Hoffmann, Hilko; Zinnikus, Ingo; Feld, Thomas; Runge, Mathias; Hinz, Oliver (Current Directions in Biomedical Engineering, 2020)
In the upcoming years, the internet of things (IoT) will enrich daily life. The combination of artificial intelligence (AI) and highly interoperable systems will bring contextsensitive multi-domain services to reality. This paper describes a concept for an AI-based smart living platform with open-HAB, a smart home middleware, andWeb of Things (WoT) as key components of our approach. The platform concept considers different stakeholders, i.e. the housing industry, service providers, and tenants. These activities are part of the Fore-Sight project, an AI-driven, context-sensitive smart living platform.
CRIS-Team Scopus Importer:2021-04-19
Keywords: interoperability; smart home; smart living; web of things

ForeSight - An AI-driven Smart Living Platform, Approach to Add Access Control to openHAB - Bauer, Jochen; Hechtel, Michael; Konrad, Christoph; Holzwarth, Martin; Hoffmann, Hilko; Feld, Thomas; Schneider, Sven; Zinnikus, Ingo; Mayr, Andreas; Franke, Jörg (Lecture Notes in Computer Science (including subseries Lecture Notes in Artificial Intelligence and Lecture Notes in Bioinformatics), 2020)
We created an approach for a smart living platform called ForeSight which consists of different modules: a service engineering module, a Web of Things (WoT)-based Internet of Things (IoT) module and an artificial intelligence (AI) component. This paper describes how openHAB, a smart home middleware, is extended to fulfill platform requirements related to a successful interaction with the IoT module of ForeSight, more precisely, to add identity and access management (IAM) to openHAB and comply with European privacy laws.
Created from Fastlane, Scopus look-up
Keywords: Architecture; Artificial intelligence; openHAB; Platform; Privacy; Smart home; Smart living

ForeSight Approach to improve Privacy and Security in the Smart Living Domain - Bauer, Jochen; Konrad, Christoph; Hechtel, Michael; Wichert, Reiner; Weigand, Christian; Dengler, Simon; Holzwarth, Martin; Franke, Jörg (Current Directions in Biomedical Engineering, 2021)
This contribution describes how to improve privacy and security for the Smart Living domain. Core elements of this approach adapt the Privacy by Design concept to the domain of smart living and extend it to enable artificial intelligence integration. To improve security, we created a minimum framework based on an existing information security management system to offer a holistic perspective on that topic. This, we think, is necessary, primarily if legacy Internet of Things devices should be supported
Created from Fastlane, Scopus look-up
Keywords: AAL; Privacy; Security; Smart Living

ForeSight - Platform Approach for Enabling AI-based Services for Smart Living - Bauer, Jochen; Hoffmann, Hilko; Feld, Thomas; Runge, Mathias; Hinz, Oliver; Mayr, Andreas; Förster, Kristina; Teske, Franz; Schäfer, Franziska; Konrad, Christoph; Franke, Jörg (How AI Impacts Urban Living and Public Health, 2019)
In future, smart home and smart living applications will enrich daily life. These applications are aware of their context, use artificial intelligence (AI) and are therefore able to recognize common use cases reliably and adapt these use cases individually with the current user in mind. This paper describes a concept for such an AI-based platform. The presented platform approach considers different stakeholders, e.g. the housing industry, service providers and tenants.
CRIS-Team Scopus Importer:2019-12-10
Keywords: Artificial intelligence; Ecosystem; Platform; Smart home; Smart living

ForeSight – User-Centered and Personalized Privacy and Security Approach for Smart Living - Bauer, Jochen; Wichert, Reiner; Konrad, Christoph; Hechtel, Michael; Dengler, Simon; Uhrmann, Simon; Ge, Mouzhi; Poller, Peter; Kahl, Denise; Ristok, Bruno; Franke, Jörg (Distributed, Ambient and Pervasive Interactions. Smart Living, Learning, Well-being and Health, Art and Creativity, 2022)
With the emerging Internet of Things (IoT) techniques in smart home applications, artificial intelligence (AI), and highly interoperable IoT s ystems enable the development of context-sensitive multi-domain services in smart homes [1]. However, while such systems create enormous challenges regarding security and privacy, the IoT practitioners may overlook certain security and privacy concerns such as European Union (EU) General Data Protection Regulation (GDPR). This paper describes the necessities to consider privacy- and security-related challenges for smart living platforms. Core elements of this contribution are a user survey to detect key aspects to fulfill users’ expectations and an in-detail description of a Gaia-X-compatible software technology stack for the smart living domain. The concept will be applied to a smart kitchen use case.<br
Keywords: Active assisted living; Gaia-X; Smart home; Smart living

Foreword by the Conference Chairman - Franke, Jörg (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
CRIS-Team Scopus Importer:2023-03-07

Four Independent Knowledge Domains to Enable an Agile, Distributed Development of User-Centred Engineering Configurators - Schäffer, Eike; Mayr, Andreas; Reichenstein, Tobias; Shafiee, Sara; Franke, Jörg (Procedia CIRP, 2021)
Robot-centric automation solutions (RAS) promise greater efficiency and consistent quality in production, relieving workers of physically demanding and dangerous tasks, especially in the times of COVID-19. Nevertheless, due to their relatively high complexity and implementation costs, RAS are only used to a limited extent by small and medium-sized manufacturing companies. As a rule, the high costs of RAS arise from custom engineering efforts, which take up to 70 percent of the acquisition costs. For this reason, it is necessary to optimise the engineering of RAS. However, software tools such as configurators have been used primarily for the individualisation of products, such as automobiles or clothing, based on variants predefined by the manufacturer, and less for the engineering of automation solutions. The development of knowledge-based systems, in particular knowledge-based engineering configurators (EC), is usually performed by few proficient experts with high development effort. One of the primary challenges in the knowledge acquisition is that several experts possess partial aspects of knowledge in an inhomogeneous, implicit form. Furthermore, there is a lack of efficient development methods for EC. By reusing knowledge elements from previous development projects, a sustainable increase in efficiency is possible. In order to enable an efficient development process of EC, we introduce a structuring model consisting of four knowledge domains (KD): knowledge about specific business cases (KD1), Best Practices as case-specific solution knowledge (KD2), logical expert knowledge (KD3) as well as semantically consistent data models for interoperability of different IT systems (KD4). As the four KD are independent, their development can be agilely divided among several teams or companies. Finally, the agile development approach is validated individually for each KD as well as comprehensively within the scope of the ROBOTOP platform for planning RAS.
Keywords: Best Practice; configurator; knowledge-based; knowledge acquisition; KBEC; engineering; planning; division of labour; automation; robot

From Descriptive to Predictive Six Sigma: Machine Learning for Predictive Maintenance - Schäfer, Franziska; Schwulera, Erik; Otten, Heiner; Franke, Jörg (IEEE Artificial Intelligence for Industries, 2019)
Ongoing changes in the field of information technology and increasing data availability in combination with open source software for data mining and machine learning algorithms require companies to rethink their process improvement strategy. For the zero defect goal within production lines, new optimization potentials arise that need to be raised. This also comprises to think ahead of already existing and well-established methods for process improvement like Six Sigma from descriptive to predictive. This paper addresses the progress of improving processes not only with descriptive analytics in retrospect, but also forward-looking predictive algorithms. We state the similarities and differences of both approaches and how to bridge the gap. Two practical use cases within the field of electronics production underline this approach and point out important steps and challenge

From Human to Robot Interaction towards Human to Robot Communication in Assembly Systems - Kambarov, Ikrom; Inoyatkhodjaev, Jamshid; Kunz, David; Brossog, Matthias; Franke, Jörg (Eurasia Proceedings of Science, Technology, Engineering and Mathematics, 2023)
The interaction between humans and robots has been a rapidly developing technology and a frequently discussed research topic in the last decade because current robots ensure the physical safety of humans during close proximity assembly operations. This interaction promises capability flexibility due to human dexterity skills and capacity flexibility due to robot accuracy. Nevertheless, in these interactions, the humans are marginally outside of the system, while the robots are seen as a crucial component of the assembly activities, which causes the systems to lack flexibility and efficiency. Therefore, this paper presents a study on Human to Robot communication in assembly systems. We conducted a systematic review of related literature and industrial applications involving human and robot interaction modes over the last decade to identify research gaps in the integration of collaborative robots into assembly systems. We believe that we are in a transformation phase from physical interaction mode towards cognitive interaction mode between humans and robots, where humans and robots are able to interact with each other during mutual working conditions and humans are able to guide robots. The main contribution of this paper is to propose a future mode of human-robot interaction in which a skilled operator performs not only physical cooperative tasks with robots but also work aided by smart technologies that allow communication with robots. This interaction mode allows for an increase in the flexibility and productivity of the assembly operation as well as t he wellbeing of the human operator in a human-centered manufacturing environment.
CRIS-Team Scopus Importer:2023-12-01
Keywords: Human robot communication; Human robot interaction; Industry 4.0; Industry 5.0

Fully automated rotor inspection apparatus with high flexibility for permanent magnet synchronous motors using an improved hall sensor line array - Meyer, Alexander Wilhelm; Heyder, Andreas; Brela, Matthäus; Urban, Nikolaus; Sparrer, Johannes; Franke, Jörg (5th International Conference on Electric Drives Production, EDPC 2015, 2015)
As a result of the market expansion of permanent magnet synchronous motors due to the increasing demand for high-performance drives for a wide range of applications such as traction drives for electric mobility, positioning drives for machine tools as well as high-precision drives for special-purpose machines and the quality demands involved, in-line capable measurement technology is needed. Thus in the area of electric drives manufacturing the rejection rate is required to be reduced by early fault detection. This can be achieved by measuring the rotor excitation field created by permanent magnets prior to the assembly of rotor and stator. In this Paper an apparatus for fully automated inspection of both internal and external rotors within a wide range of dimensions is presented. This is done with the aid of a one dimensional Hall-Sensor line array, which is manufactured with high accuracy and the use of an open source CNC system. The presented device is capable for in-line operation at the end of the rotor assembly process chain to detect possible magnetization and assembly faults prior to the final assembly of the electric drive by visualization of the rotor excitation field.

Functionally integrated additive manufactured rotor components for torque-dense aircraft electric motors - von Lindenfels, Johannes; Posch, Dennis; Ihne, Thorsten; Franke, Jörg; Kühl, Alexander (Procedia CIRP, 2023)
In dealing with emissions targets worldwide, fundamental questions about the future arise for commercial aviation. The resulting consequences for aviation require efforts to make air traffic CO2 neutral. In this context, electrification is an important building block to enable the aviation industry to provide transport in the future with increasing traffic volumes. To achieve this goal, electric motors for flight operation must have a high power and torque density and operate as energy-efficiently as possible. The PM synchronous motors predominantly proposed for such applications have above average efficiencies but could provide higher peak powers if they could be thermally more loaded. In particular, the sensitive permanent magnets lose efficiency as the operating temperature of the electric motor increases, reducing the maximum possible torque of the motor. Since conventional rotor construction methods limit the design, additive manufacturing is used to develop a rotor design that allows the rotor magnets to be cooled in close range to their contours. In addition, by selective laser melting mechanical, thermal, and magnetic functions are integrated. A process for hybrid manufacturing of novel rotor topologies is proposed. For this purpose, the rather conventional rotor topology is replaced by an additive function-integrated component for a reference electric motor. By means of an FEM analysis, it was shown that the mechanical strength of the alternative fixation method is maintained. Using adequate design guidelines, the AM structural components were fabricated in aluminum and an iron-nickel alloy and the permanent magnets were secured on it using 1K-epoxy adhesive. CFD analysis was used to simulate the flow conditions and heat transfer to the coolant in the internal structures of the AM components. Finally, the effect of the integrated cooling function was verified with an experimental setup. The results show that the torque influencing factor of the magnetic induction can be increased.<br
Keywords: Additive manufacturing; PMSM; Electric aviation; Magnetics; cooling system; Halbach array

Fundamental mechanisms and their interactions in shear‐clinching technology and investigation of the process robustness - Wiesenmayer, Sebastian; Han, D.; Müller, Manuel; Hoerhold, R.; Meschut, G.; Merklein, Marion (Materialwissenschaft und Werkstofftechnik, 2019)
The compliance with increasingly stricter emission standards is a challenge for the automotive industry, which requires the utilization of lightweight materials e. g. aluminium and high-strength steels. Hereby, the load-optimized design of body parts and the reduction of wall thicknesses are enabled. But, due to the use of dissimilar materials, common joining technologies are reaching their limits. On the one hand, joining by welding is often not possible because of different melting temperatures. On the other hand, joining by forming with additional fasteners increases the cycle time and the costs. However, joining by forming without fasteners is often limited by the mechanical properties of the joining partners. The innovative shear-clinching technology combines shear-cutting and clinching in a single stage process and thereby enables joining by forming of materials with high differences regarding their mechanical properties. However, by the combination of the sub-processes cutting and joining, the complexity of the technology is increased. Thus, within the scope of this work, the fundamental mechanisms in shear-clinching and their interactions as well as the robustness of the process are analysed, in order to promote the applicability of the technology.
CRIS-Team WoS Importer:2019-08-09

Fusing Low-cost Sensor Data for Localization and Mapping of Automated Guided Vehicle Fleets in Indoor Applications - Ramer, Christina; Seßner, Julian; Scholz, Michael; Zhang, Xu; Franke, Jörg (2015)
This paper describes the joint use of external and on-board low-cost sensors for small to mid-size automated guided vehicles (AGVs) in varying indoor applications. Localization and mapping for navigation purposes of multi-scale vehicle fleets is achieved by combining fixed, one-time calibrated cameras with odometry information and cheap LIDAR (Light detection and ranging) and collision avoidance sensors, which are mounted on the vehicles. Our approach is scalable and applies to different domains, as logistics in production environments or hospital facilities. Experiments show that the proposed system concept, based on low-cost units, reaches sufficient accuracy in real-time and could therefore be a promising solution for the target applications.

Galvanic plating for 3D-MID applications - Kordaß, Timo; Franke, Jörg (Proceedings of the 2014 37th International Spring Seminar on Electronics Technology, ISSE 2014, 2014)
This paper gives an overview about the advantage of galvanic plating for 3D-MIDs. At first it is explained how the laser direct structuring process is proceeded. Exemplary on a serial application for motorcycles it shows the challenges for the chemical standard plating in the serial processes in the first part. The second part illustrates the differences in the plating processes between the galvanic and the chemical precipitation. The advantages with major coating thickness for further developed applications are mentioned. It is also given the particular specifics need to be considered in the development for the galvanic process.
CRIS-Team Scopus Importer:2023-03-07

Ganzheitliche und auf maschinellen Lernverfahren basierende Qualitätsüberwachung - Nguyen, Huong Giang; Scheck, Albert; Hofmann, Bernd; Meiners, Moritz; Neubauer, Stefan; Schäfer, Alexander; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2023)
Die Kontakt- und Leitungsverarbeitung ist charakterisiert durch eine hohe Komponentenvielfalt, kurze Zykluszeiten und steigende Anforderungen hinsichtlich Qualität, Dokumentation und Rückverfolgbarkeit. Mit dem Ziel, diese Rahmenbedingungen zu erfüllen, wird in diesem Beitrag eine holistische und auf maschinellen Lernverfahren basierende Qualitätsüberwachung vorgestellt. Darüber hinaus liegt der Qualitätsüberwachung die intelligente Analyse von Crimpkraftkurven zugrunde. Die Auswertung von Bilddaten und Zeitreihen ermöglicht die Fehlererkennung und Anomaliedetektion an der Maschine, ohne dass es zu Einbußen in der Taktzeit kommt. Für die Visualisierung und Werkerakzeptanz der Qualitätsparameter und Prognosen der Modelle wird das Thema Erklärbarkeit in der vorgestellten Qualitätsüberwachung besonders betrachtet.<br
CRIS-Team Scopus Importer:2023-05-05
Keywords: Automatische optische Inspektion; Crimpkraftkurvenüberwachung; Crimpverbindung; Deep Learning; Kabelsatz; Kontakt-; Leitungsverarbeitung; Maschinelles Lernen; Qualitätsüberwachung; verarbeitung

Generation of 3D Functional Structures for High- Frequency Applications by Printing Technologies - Ankenbrand, Markus; Scheetz, Matthias; Franke, Jörg; Lomakin, Konstantin; Sippel, Mark; Gold, Gerald; Helmreich, Klaus (2018 13th International Congress Molded Interconnect Devices (MID), 2018)
The following topics are dealt with: polymers; adhesion; rapid prototyping (industrial); mechatronics; aerosols; injection moulding; moulding; three-dimensional printing; metallisation; electrical resistivit

Generation of 3-dimensional power modules for high temperature applications by thermal copper coating processes - Hensel, Alexander; Schwarzer, Christian; Merz, Corinna; Stoll, Thomas; Kaloudis, Michael; Franke, Jörg (2019 IEEE 21st Electronics Packaging Technology Conference, EPTC 2019, 2019)
The market of power electronics is a rapidly growing field with many new trends and technologies. Rising junction temperatures, progressive miniaturization and high demanding application environments result in increasing requirements regarding the efficiency, lifetime expectation and flexibility of modern power electronic devices. Therefore, a novel approach to adapt the 3-dimensional mechatronic integrated device (3D-MID) technology has been investigated. By combining innovative metallization processes like plasma-based coating technologies with robust substrate materials such as ceramics and superior interconnection technologies like pressureless silver-sintering, the manufacturing of highly integrated and highly efficient power modules will be evaluated. Therefore, a ceramic substrate is coated with a selective structured copper layer to generate the electric circuit path on which the bare-die components like sensors or power switches are mounted. The top-level interconnection can be generated by standard process like Al-wire bonding or even Cu-wire bonding technologies. Since the current industry standard, is almost at its limit with regards to space efficient module design and thermal management capabilities. This approach enables even the design of spatial circuit carries which allows an improved freedom of design concerning the functional integration in small spaces at harsh environments, while the usage of high performance materials and processes expands current limitations regarding as well the operating temperature and ambient temperature.
CRIS-Team Scopus Importer:2021-04-20

Generation of 3D Silicone Models of Anatomic Soft Tissue Structures - A Comparison of Direct 3D Printing and Molding Techniques - Riedle, Hannah; Seitz, Vera; Schraudolf, Larissa; Franke, Jörg (2018 IEEE-EMBS CONFERENCE ON BIOMEDICAL ENGINEERING AND SCIENCES (IECBES), 2018)
CRIS-Team WoS Importer:2019-02-27

Generation of Printed Electronics on Thermal Sensitive Substrates by Laser Assisted Sintering of Nanoparticle Inks - Mayer, Edgar; Stichel, Thomas; Roth, Stephan; Neermann, Simone; Franke, Jörg; Schmidt, Michael (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
Direct printing technologies enable the generation of arbitrary electrical conductive structures on 3D surfaces and thus the fabrication of new and innovative mechatronic integrated devices (MID). In order to fabricate electrical circuits, a new approach using a laser beam for sintering a silverbased nanoparticle ink is investigated, reducing the thermal load on the device by a selective energy input compared to a standardized furnace process. Thus, processing of temperature sensitive and low-cost substrate materials for applications such as covering or trim parts is enabled. However, laser assisted generation of highly conductive printed structures is often accompanied by defects such as line deformations and requires a deeper understanding regarding the influence of the laser process on the production of defect-free circuits. This paper explores the benefits and limits of laser assisted sintering of printed electronics promising a fast and flexible production of complex conductive circuits on a small time scale in contrast to furnace sintering processes. For an evaluation of characteristic properties, four point measurements and adhesion tests are carried out on the conductive structures. In order to guarantee safe and reliable operation of the printed structures, the long-term characteristics are determined by means of a temperature change test.
CRIS-Team Scopus Importer:2021-04-02
Keywords: Aerosol Jet; Direct Printing; Electrical Conductive Circuits; Nanoparticle Ink; Sintering by Laser Radiation

Generation of RF Structures on Additively Manufactured Substrates by Printed Electronics and Laser Structuring - Ankenbrand, Markus; Panusch, David; Utsch, Daniel; Banea, Kevin; Ehrngruber, Michael; Gold, Gerald; Helmreich, Klaus; Franke, Jörg (Proceedings of the SMTA Pan Pacific Microelectronics Symposium 2023, 2023)
In this work, printed electronics and laser processes are utilized to generate radio frequency (RF) structures for the X-band on additively manufactured substrates. The substrates are generated by Fused Filament Fabrication (FFF) with various materials. Conductive structures are applied with the processes Piezojet, Nanojet and Laser Direct Structuring (LDS). Piezojet is a drop-on-demand inkjet process that can print a wide range of inks and pastes with viscosities up to 200,000 mPas. Typical line widths are in the range of 300 - 500 μm. Nanojet uses ultra-sonic atomization to create an aerosol from a functional ink. In the nozzle, the aerosol is focused by an additional gas flow, which enables line widths as fine as 20 μm. Both Piezojet and Nanojet require a post-treatment step to dry or sinter the applied inks in order to achieve full conductivity. The LDS process works with a laser-activatable additive that is compounded into the material. Circuit tracks are generated by laser-scanning the layout on the substrate surface. The areas activated in this process are then metallized in an electroless plating process to achieve conducting paths. Moreover, the LDS-laser can also be used to smoothen the 3D-printed substrate surfaces and for sintering and trimming the circuits printed with Piezojet and Nanojet. In order to evaluate the different process and material combinations, the following coplanar structures are printed on additively manufactured substrates: Transmission line sections, a bandpass and a resonator. A network analyzer is used to measure the scattering parameters of the printed structures. With the measured magnitude and phase together with the geometry of the lines, an estimation for the relative permittivity εr can be obtained. This parameter is later used in the design process of an additively manufactured helix antenna. This antenna type offers a small form factor in combination with high gain and bandwidth, while radiating a signal of circular polarization. Many RF applications like satellite communication or radar imaging rely on circular polarized antennas [1,2]. The helix antenna is manufactured with the above-described processes in a 5-axis motion syste
Keywords: Additive Manufacturing; Printed Electronics; Microwave Technology; Mechatronic Integrated Devices; Helix antenna; X-band

Generic design of an anatomical heart model optimized for additive manufacturing with silicone - Riedle, Hannah; Ghazy, Ahmed; Seufert, Anna; Seitz, Vera; Dorweiler, Bernhard; Franke, Jörg (Rapid Prototyping Journal, 2020)
Purpose: The purpose of this study is the generation of a thorough generic heart model optimized for direct 3D printing with silicone elastomers. Design/methodology/approach: The base of the model design is segmentation of CT data, followed by a generic adaption and a constructive enhancement. The model is 3D printed with silicone. An evaluation of the physical model gives indications about its benefits and weaknesses. Findings: The results show the feasibility of a generic design while maintaining anatomical correctness and the benefit of the generic approach to quickly derive a multiplicity of healthy and pathological versions from one single model. The material properties of the silicone model are sufficient for simulation, but the results of the evaluation indicate possible improvements, as for most anatomical features, the used silicone is too hard and too stretchable. Originality/value: Previous developments mostly focus on patient-specific heart models. In contrast, this study sets out to explore the possibility and benefits of a generic approach. Standardized validated models would allow comparability in surgical simulation.
CRIS-Team Scopus Importer:2020-12-25
Keywords: 3D printing; Generic design; Heart model; Medical education; Silicone; Surgical simulation

Geometry-Based 6D-Pose Visual Servoing System Enabling Accuracy Improvements of Industrial Robots - Buschhaus, Arnd; Franke, Jörg; Grünsteudel, Holger (IEEE 2016 International Conference on Advanced Mechatronic Systems, 2016)
Keywords: B|Mech

Geschäftsmodell-Muster für digitale B2B-Plattformen - Löwen, Ulrich; Hartner, Fabian (VDI-Berichte 2375, 2020)

Gestaltung einer Fertigungsumgebung für Ladesäulen: Konzeption einer schlanken, ressourceneffizienten und flexiblen Montage - Fauser, Florian; Michl, Markus; Franke, Jörg (wt Werkstattstechnik - Online, 2016)
Due to the increasing significance of electromobility, the need for charging stations rises. To ensure that the growing demand can be met, production has to be adjusted to the new requirements. The production environment has to provide a high rate of flexibility to enable reacting to the development of electromobility. The article describes solutions covering the topics layout and material flow, workplace design and tool management as well as purchasing and warehousing.
CRIS-Team Scopus Importer:2023-03-07

Gesture Recognition with Sensor Data Fusion of Two Complementary Sensing Methods - Landgraf, Maximilian; Yoo, In Seong; Seßner, Julian; Mooser, Maximilian; Kaufmann, Dominik; Mattejat, David; Reitelshöfer, Sebastian; Franke, Jörg (7th IEEE International Conference on Biomedical Robotics and Biomechatronics (Biorob), 2018)

Gradual tool-based optimization of engineering processes aiming at a knowledge-based configuration of robot-based automation solutions - Schäffer, Eike; Mayr, Andreas; Huber, Tobias; Höflinger, Tobias; Einecke, Matthias; Franke, Jörg (Procedia CIRP, 2019)
Due to the growing individualization and ever shorter product life cycles, the engineering of automation solutions is facing increasing challenges. The rethinking of common engineering processes and the inclusion of knowledge-based approaches are considered inevitable. However, existing optimization measures often do not meet the actual problems as many approaches in academics are still too immature for practical use. Therefore, a rather simple procedure for the optimization of knowledge-intensive engineering processes is presented here, mainly relying on the incremental, tool-based creation of a common knowledge base. The procedure is validated using the example of a German automotive supplier. Building on this, the further development towards a knowledge-based configuration platform for robot-based automation solutions is illustrated in the outlook.<br
Keywords: systems engineering; robot-based automation solution; knowledge management; knowledge-based engineering; configuration

Grasping devices and methods in automated production processes - Fantoni, Gualtiero; Santochi, Marco; Dini, Gino; Tracht, Kirsten; Scholz-Reiter, Bernd; Fleischer, Juergen; Lien, Terje Kristoffer; Seliger, Guenther; Reinhart, Gunther; Franke, Jörg; Hansen, Hans Norgaard; Verl, Alexander (CIRP Annals - Manufacturing Technology, 2014)
In automated production processes grasping devices and methods play a crucial role in the handling of many parts, components and products. This keynote paper starts with a classification of grasping phases, describes how different principles are adopted at different scales in different applications and continues explaining different releasing strategies and principles. Then the paper classifies the numerous sensors used to monitor the effectiveness of grasping (part presence, exchanged force, stick-slip transitions, etc.). Later the grasping and releasing problems in different fields (from mechanical assembly to disassembly, from aerospace to food industry, from textile to logistics) are discussed. Finally, the most recent research is reviewed in order to introduce the new trends in grasping. They provide an outlook on the future of both grippers and robotic hands in automated production processes. © 2014 CIRP.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Automation; Grippers

Green cockpit: Transparency on energy consumption in manufacturing companies - Rackow, Tobias; Javied, Tallal; Donhauser, Toni; Martin, Andreas; Schuderer, Peter; Franke, Jörg (12th Global Conference on Sustainable Manufacturing, GCSM 2014, 2015)
Companies are forced by rising energy costs to seize control of their energy consumption to maintain contestability. Therefore, transparency over the companies' energy flux along the production process is required. Energy data management software is helpful, but cost-intensive. Hence, especially small and medium sized enterprises (SME) spare this investment. In this paper, the requirements for an energy controlling infrastructure in SME are elaborated, followed by a deduced software-architecture which supports the respective controlling structure. Further, the prototypical realization of the corresponding tool "Green-Cockpit" will be presented. The free of cost, open source and web-based tool is designed to help companies monitor, interpret, analyze, plan and report their energy consumption. The Green Cockpit tool outperforms other energy management software at management disciplines with its ability to not only analyze energy consumption, but plan and control it additionally.
Keywords: Energy controlling; Energy management; Open source data management; Operations management

Green Energy Management Portal - Infrastrukturprojekt der Green Factory Bavaria - Brandmeier, Markus Andreas (Tagungsband zum 3. Green Factory Bavaria Kolloquium 2016, 2016)

Green Energy Management Portal - Infrastrukturprojekt der Green Factory Bavaria - Brandmeier, Markus Andreas (Tagungsband zum 1. Green Factory Bavaria Kolloquium 2014, 2014)

Green Energy Management Portal - Infrastrukturprojekt der Green Factory Bavaria - Brandmeier, Markus Andreas (Tagungsband zum 2. Green Factory Bavaria Kolloquium 2015, 2015)

Green Energy Management Portal – Knowledge and Project Management for Energy Efficiency Projects - Brandmeier, Markus Andreas; Rummler, Kerstin; Brossog, Matthias; Franke, Jörg (Energy Effiency in Strategy of Sustainable Production, 2015)
Keywords: Energy efficiency; Project management; Knowledge management systems

Green factories Bavaria: A network of distributed learning factories for energy efficient production - Kreitlein, Sven; Höft, Annika; Schwender, Sabrina; Franke, Jörg (Procedia CIRP, 2015)
The Green Factory Bavaria project contributes to the ability of Bavarian companies to improve their resource consumption. The main impulses include the knowledge transfer of applied research in the industry and the organization of experience exchange among companies. Therefore, Bavarian-wide so-called Green Factories for energy-efficient production are being developed and expanded, see, for instance, the learning and research platforms at the Technische Universitát in Munich, the Friedrich-Alexander-University Erlangen-Núrnberg as well as at Universities of Applied Sciences in Amberg/Weiden, Ansbach, Coburg, Hof, Nuremberg, and Schweinfurt/Wúrzburg. Together, universities and companies are developing technical solutions and methodological approaches for the reduction of resource consumption and are presenting the latest Green Factories findings, where theoretical training can be made comprehensible through demonstration. The companies are supported through individual consulting services, while internet-based checklists and benchmarking analyzes help to determine the need for action. At each location specific Bavarian-wide coordinated technology priorities as well as cross-cutting issues are presented. Joint activities are processed, thereby ensuring the exchange of information among the institutions as well as with the industry. In the model factories for energy-efficient manufacturing innovative industrial partners shall receive the opportunity to demonstrate advanced techniques and technologies for energy-efficient production in the available laboratory and production areas, develop hand-in-hand with scientists from the participating research institutions, build a network among themselves, and circulate the findings effectively to users and students.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy-efficient production; Interdisciplinary research-groups; Knowledge exchange

Großserientaugliche Nadelwickeltechnik für verteilte Wicklungen im Anwendungsfall der E-Traktionsantriebe: Der Technischen Fakultät der Friedrich-Alexander-Universität Erlangen-Nürnberg zur Erlangung des Doktorgrades Dr.-Ingenieur - Stenzel, Peer; Franke, Jörg; Piepenbreier, Bernhard; Endisch, Christian (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2017)
Einleitung Innerhalb seiner nunmehr über einhundertjährigen Geschichte hat sich das Automobil zum beliebtesten Individualtransportmittel entwickelt [1]. Dabei konnte sich der Verbrennungsmotor auf Basis fossiler Kraftstoffe gegenüber anderen Antriebsarten durchsetzen [2]. Trotz vieler verbrauchssenkender Innovationen in der sogenannten konventionellen Antriebstechnik nehmen die verkehrsbedingten CO2-Emissionen aufgrund des weltweit steigenden Verkehrsaufkommens weiterhin zu [3, 4]. In den Jahren von 2000 bis 2010 betrug die Zunahme der straßenverkehrsbe-dingten CO2-Emissionen 14 % [3], während im gleichen Zeitraum der weltweite KFZ-Bestand um 33 % auf mehr als eine Mrd. Fahrzeuge anstieg [5]. Um den CO2-Ausstoß einzudämmen, hat die Europäische Kommission daher ein gesetzliches Limit in Höhe von 95 g CO2 / km für den Durchschnittsflottenverbrauch aller in der EU neu zugelassenen PKWs beschlossen, das stufenweise in Kraft tritt [6]. Die Emissionen werden über den Neuen Europäischen Fahrzyklus (NEFZ) ermittelt. Bei Nichteinhaltung drohen empfindliche Strafen [1]. Auch andere Länder, wie die USA, Japan und China haben Verbrauchs-, bzw. Emissionsvorschriften. Diese Vorschriften stellen insbesondere die Premiumhersteller, wie beispielsweise Audi, BMW und Daimler, vor große Herausforderungen, da deren Kunden vorzugsweise leistungsstärkere Modelle kaufen, die einen höheren Kraftstoffverbrauch zur Folge haben. Aus diesem Grund gibt es bei den Automobilherstellern Bestrebungen, den Verbrennungsmotor teilweise oder vollständig durch den Elektromotor zu substituieren. Für die Kundenakzeptanz ist dabei entscheidend, dass die Hybrid- (HEV) und Elektrofahrzeuge (BEV) im Vergleich zum konventionell angetriebenen Fahrzeug vergleichbare Preise, ausreichende Reichweiten und möglichst weiteren exklusiven Zusatznutzen, wie besseres Beschleunigungsverhalten oder geringere Wartungszyklen aufweisen. Daraus ergeben sich für die für den Antrieb infrage kommenden Drehstrommaschinen unter anderem die Forderungen nach einer hohen Leistungsdichte und einem hohen Wirkungsgrad über ein breites Drehmoment-Drehzahl-Band sowie nach einer wirtschaftlichen Herstellbarkeit. Während die elektromagnetische Auslegung der E-Maschine Gegenstand von vielen Untersu-chungen und Veröffentlichungen ist, wurde in der Vergangenheit der Fertigung von Elektromaschinen hingegen in Literatur und Forschung nur wenig Beachtung geschenkt. Dabei liegt ein wesentliches Entwicklungspotenzial in der Fertigung, da die Herstellungstechnologien, und insbesondere die Wickeltechnologie des Stators, einerseits die Herstellungskosten bestimmen und andererseits die elektromagne-tische Auslegung und die Konstruktion des Elektromotors einschränken. Dies geschieht in Form von erreichbaren Kupferfüllfaktoren, umsetzbaren Wickelschemata und Bauraumforderungen durch die Wickelkopfhöhe. Während die konzentrierte Wicklung als eine der zwei Ausprägungsformen der Drehstromwicklungen gut industrialisiert ist und viele Automatisierungsmöglichkeiten bietet [7], existieren für 1 Einleitung 2 die andere Wicklungsart, die sogenannte verteilte Wicklung, nur wenige wickeltechnische Möglichkeiten, die großserientauglich sind und gute Produkteigen-schaften ermöglichen. Dies ist insofern nachteilig, da die verteilte Wicklung ein wesentlich breiteres Anwendungsspektrum hat und sich die konzentrierte Wicklung, wie in Kapitel 2 gezeigt wird, für Asynchronmaschinen und Achsantriebe in Elektro-Fahrzeugen nicht gut eignet. Im Falle von verteilten Runddrahtwicklungen wird üblicherweise die Einziehtechnik verwendet, die zwar seit mehreren Jahrzehnten etabliert [8], jedoch aufgrund vieler manueller Tätigkeiten nur bedingt großserien-tauglich ist. Darüber hinaus sind mit der Einziehtechnologie durch die prinzipbedingte Wildwicklung nur mittlere Kupferfüllfaktoren erzielbar. Eine Alternative bietet die Nadelwickeltechnik, die Potenzial bezüglich Kupferfüllfaktor und Automatisierbarkeit aufweist, bisher für verteilte Wicklungen jedoch nur bei Industrieantrieben zur Anwendung kam, welche geringere Anforderungen an Wickelkopfhöhe und Kupferfüllfaktor stellen. Vor diesem Hintergrund ergibt sich die Aufgabenstellung dieser Arbeit, die Nadelwickeltechnik für verteilte Wicklungen von Traktionsantrieben weiter-zuentwickeln und auf die automobilen Bedürfnisse anzupassen. Dies bedeutet, dass der Wickelprozess samt nachgelagerten Prozessschritten möglichst vollständig automatisierbar und damit großserientauglich werden soll. Darüber hinaus sind die Produkteigenschaften der E-Traktionsmaschine zu optimieren. Zunächst werden in Kapitel 2 die Grundlagen elektrischer Drehstrommaschinen sowie deren Aufbau beschrieben. Anschließend werden die zwei Ausprägungen der Drehstromwicklungen - die konzentrierte und die verteilte Wicklung - erläutert. In Kapitel 3 erfolgt die Beschreibung alternativer Herstellverfahren für verteilte Wicklungen sowie die Erläuterung des Zusammenhangs zwischen Produkteigen-schaften und Fertigung. Darauf aufbauend werden die Entwicklungs- und Optimierungsziele für das Nadelwickelverfahren abgeleitet. Neben dem allgemeinen Automatisierungsziel werden die Wickelkopfhöhe und der Kupferfüllfaktor, bzw. der Wicklungswiderstand als wesentliche Produktbeeinflussungsmöglichkeiten und damit Optimierungsziele identifiziert. Darüber hinaus wird aus den Ergebnissen bezüglich des Zusammenhangs zwischen Produkteigenschaften und Wickelverfahren der Drahtzugkraft eine besondere Bedeutung für den Wicklungswiderstand bei-gemessen, was überprüft werden soll. Zudem wird festgelegt, dass für die weiteren Entwicklungen und Untersuchungen eine Asynchronmaschine aus einem aktuellen Fahrzeugprojekt verwendet wird. Mithilfe von experimentellen Wickelversuchen an einer Parallelkinematik werden in Kapitel 4 der Einfluss der Drahtzugkraft auf den Wicklungswiderstand sowie der Einfluss der Nadelgeometrie auf die Drahtzugkraft untersucht. In Kapitel 5 erfolgt die Konzeptentwicklung zur Erhöhung des Füllfaktors unter Nutzung der Nadelwickeltechnik. Dabei wird ein Lösungsansatz erarbeitet und 1 Einleitung 3 prototypisch an einer Parallelkinematik erprobt. Die Grundidee besteht darin, mithilfe einer gebogenen Wickelnadel die schwer zugänglichen Bereiche der Nut zu erreichen und den Draht unmittelbar an der gewünschten Position zu platzieren, um so eine lagegenaue Wicklung zu erreichen. Da der Ansatz für die Implementierung in eine industrielle Nadelwickelanlage, unter anderem aufgrund des Bauraumbedarfs und der zusätzlichen Masse durch den Servoantrieb, herausfordernd ist, wird auf Basis der Versuchsergebnisse ein zweiter Ansatz mit einem kinematisch optimierten Prinzip entwickelt. In Kapitel 6 wird ein Ansatz zur Optimierung des Wickelkopfes beschrieben. Ausgehend von einigen grundsätzlichen überlegungen zur Wickelkopfoptimierung werden mehrere Lösungsansätze erarbeitet und bewertet. Der Ansatz eines temporär gefügten Wickelwerkzeugs zeigt dabei das größte Potenzial und wird daraufhin konstruktiv umgesetzt. Aufgrund der hohen wirkenden Wickelkräfte wird ein FE-Modell des Werkzeugs entwickelt und validiert. Die Wickelkräfte als Eingangsparameter für das FE-Modell werden im Versuch experimentell ermittelt. Anschließend wird zum Nachweis der Prinziptauglichkeit mithilfe der weiter-entwickelten Nadelwickelmethode eine E-Maschine prototypisch aufgebaut. In Kapitel 7 werden die Produkteigenschaften des nadelgewickelten Prototyps über Prüfstandmessungen ermittelt und mit denen einer Referenzmaschine verglichen, um die Nadelwickeltechnologie hinsichtlich ihrer Auswirkungen auf das Betriebsver-halten zu untersuchen. Den Abschluss der Arbeit bildet eine Wirtschaftlichkeitsunter-suchung in Kapitel 8, bei der das weiterentwickelte Nadelwickelverfahren mit der Einziehtechnik verglichen wird.
Keywords: Anlagenplanung; Assembling; assembly; assembly machines; Coil winding; E|DRIVE; E|DRIVE; Automated Winding Assembly; Stator; Key Words: Robot-based; E|DRIVE; Automated Winding Assembly; Stator; Robot- based; Cover; E|DRIVE; electromagnetic actuators; magnetic stray fields; nondestructive measurement system; GMR-sensor; E|DRIVE; Elektromaschinenbau; Füllfaktor; Effizienz; Mechatronics; production; Production engineering; Produktion; system integration; Technology; winding of HF-litz wires; Wires

H2rs: Deducing evolutionary and functionally important residue positions by means of an entropy and similarity based analysis of multiple sequence alignments - Janda, Jan-Oliver; Popal, Ajmal; Bauer, Jochen; Busch, Markus; Klocke, Michael; Spitzer, Wolfgang; Keller, Jörg; Merkl, Rainer (Bioinformatics, 2014)
Keywords: Algorithmik; Bioinformatik; E|Home; Software Engineering

Hall measurement method for the detection of material defects in plastic-embedded permanent magnets of rotors - Brela, Matthäus; Michalski, Markus; Gebhardt, Hans Joerg; Franke, Jörg (IECON Proceedings (Industrial Electronics Conference), 2013)
The efficiency of electric drives is determined by the mechanical and magnetic properties of the functional elements, such as stator and rotor. Due to the electromagnetic interaction with the magnetic field, generated by the stator, the rotor transforms the magnetic energy into a rotational motion. It is characterized by its magnetization, its magnetic field strength, the field distribution and its geometric dimensions. The current challenge is to produce electrical drives with minimal loss. This requires ensuring the magnetic characteristics of the rotors. Errors that can occur during manufacture are cracks, blowholes or inclusions in the permanent magnet. Those can lead to commutation problems or to increased noise. For this purpose, a non-destructive and non-contact measurement method, based on the measurement of the magnetic field with Hall-effect sensors to detect defects in plastic-bonded permanent magnet rotors was developed. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Actuators and System Integration; Diagnostic and Prognostic; Fault Detection; Permanent Magnet Machines; Sensors

Hard encapsulation of automotive power modules by epoxy potting-encapsulant selection assisted by thermo-mechanical simulation - Sprenger, Mario; Forndran, Freerik; Ottinger, Bettina; Dammann, Thomas; Erben, Bettina; Sippel, Marcel; Franke, Jörg (2022 23rd International Conference on Thermal, Mechanical and Multi-Physics Simulation and Experiments in Microelectronics and Microsystems, EuroSimE 2022, 2022)
Encapsulation with soft silicone gel by potting is the standard technology in packaging of automotive power modules with sixpack topology and highest power densities. Large-area potting of liquid hard encapsulant material is another option for realization of a hard encapsulation. Large substrate, heatsink and module size in general, multi-material stack-up, heavy cyclic thermal loads during operation, high temperature and high voltage operation possess challenges to the material choice for hard encapsulation. Within this study different power module packages have been hard encapsulated, delamination and brittle fracture of the encapsulant as well as damage of the encapsulated structure through the encapsulant are thereby observed. Corresponding thermo-mechanical simulations were set up and used to detect and investigate the failure reasons. It was found that mechanical properties of encapsulants are well adapted to the encapsulated power module packaging structures. Special attention has therefore to be put on geometrical specialties such as etching trenches and bus bar connections.
CRIS-Team Scopus Importer:2022-05-20

Hardware-Software Co-Simulation of Self-Organizing Smart Home Networks: Who am I and where are the others? - Kleinert, Bruno; Schäfer, Franziska; Weiß, Simone; Bakakeu Ngassam, Romuald Jupiter; Fey, Dietmar (2016)

HealthRec - Empfehlungssystem zur Behandlung des metabolischen Syndroms im Smart Home - Bauer, Jochen; Michl, Markus; Kettschau, Anna-Katharina; Wiebe, Sergej; Vierow, Verena; Ge, Mouzhi; Franke, Jörg (Zukunft Lebensräume - Gesundheit, Selbstständigkeit und Komfort im demografischen Wandel Konzepte und Technologien für die Wohnungs-, Immobilien-, Gesundheits- und Pflegewirtschaft, 2016)

Heizsystem zur Schaffung eines angenehmen und belastungsarmen Raumklimas in Altbauten - Hein, Moritz; Stöber, Ralf; Fischerauer, Gerhard; Bauer, Jochen; Bürner, Johannes; Kettschau, Anna-Katharina; Franke, Jörg; Feller, Martin (Zukunft Lebensräume - Gesundheit, Selbstständigkeit und Komfort im demografischen Wandel Konzepte und Technologien für die Wohnungs-, Immobilien-, Gesundheits- und Pflegewirtschaft, 2016)

Herstellung räumlicher Schaltungsträger mit keramischen Materialien mittels digitaler Fertigungsverfahren - Utsch, Daniel; Milich, Niklas; Ankenbrand, Markus; Franke, Jörg (Elektronische Baugruppen und Leiterplatten EBL 2022, 2022)

Herstellungsverfahren gestapelter dielektrischer Elastomeraktoren und Vorbereitung für den Einsatz in mobilen Kinematiken - Landgraf, Maximilian; Reitelshöfer, Sebastian; Franke, Jörg (2013)

Heuristical Solution for Scheduling Single Stage Parallel Machines Production of Calcium Silicate Masonry Units with Sequence-Dependent Changeover Times to Improve Energy Efficiency - Baier, Lukas; Donhauser, Toni; Schuderer, Peter; Franke, Jörg (Applied Mechanics and Materials, 2017)
Determination of optimal production schedules is a complex combinatorial task and may be dependent on various objectives. Hence, many mathematical problem formulations and solving strategies have already been proposed each considering individually constrained applications in order to minimize non-value-adding times or other cost driving factors. Nevertheless, obtaining optimal solutions is still related to extensive computational resources and time efforts. As a result, heuristical approaches or combinations of heuristics and exact algorithms are of major importance when it comes to automatically creating optimal production schedules. Considering the manufacturing of calcium silicate masonry units (CS), this paper describes an advancement for the General Lot-Sizing Problem (GLSP) in order to allow sequence-dependent changeovers as well as multiple different machines and backlogging (GLSPPLB). For solving the GLSPPLB, a heuristical algorithm consisting of neighborhood search and threshold accepting techniques was implemented. To validate the results of the heuristic and compare required computational resources to accurate mathematical solvers, a test set of a realistic scenario has been used. The developed heuristic is able to create nearly optimal production schedules and thereby minimizing the trade off between energy demand regarding idle times of production machinery and stocks. It is transferable to every discrete single stage production with similar constraints and can be used as an input for further simulations to improve energy consumption.
Keywords: backlogging; GLSPPLB; lot sizing; parallel machines; sequence-dependent changeover times; single stage

Hierarchical And Flexible Navigation For AGVs In Autonomous Mixed Indoor And Outdoor Operation - Zwingel, Maximilian; Baier, Lukas; Blank, Andreas; Franke, Jörg (Proceedings of the 2nd Conference on Production Systems and Logistics (CPSL 2021), 2021)
Globalized markets require a high degree of flexibility in existing production and logistics environments. Flexible intralogistics systems are one key component for enabling versatile production by ensuring material supply and providing a dynamic link between different production stages. Challenged by historically grown production layouts and the increasing need of adaptable supply routes due to new forms of workshop organization like matrix production, state-of-the art approaches for intralogistics systems based on automated guided vehicles (AGVs) are not sufficient for mixed indoor and outdoor operation. In order to enable a truly flexible operation of systems in these mixed indoor and outdoor scenarios, new solutions for navigation and planning as well as increased autonomous capabilities of AGVs need to be focused (e.g. adaptive detection of driveable regions). In this paper, we propose an approach of hierarchical navigation utilizing a node-based representation of the production and logistics environment to allow flexible pathing and routing of AGVs. Based on inherent information of each node, autonomous capabilities of AGVs are activated according to the requirements of the area of operation. To prove reliability of the proposed hierarchical and flexible navigation, an evaluation of the approach is performed utilizing an industrial mobile system enhanced by autonomous capabilities in varying real-world cross-building scenarios.
Keywords: Autonomous Tow Truck Systems; Network Based Pathing and Routing; Digitalized Production Environment

Highly Dynamic 2-DOF Cable-Driven Robotic Wrist based on a Novel Topology - Nemoto, Takeru; Walter, Jonas; Bachmann, Christian; Gerlich, Matthias; Reitelshöfer, Sebastian; Franke, Jörg (IEEE Robotics and Automation Letters, 2022)
This paper presents a highly dynamic cable-driven robotic wrist with two degrees of freedom (DOFs). It is based on a novel topology that combines three passive cables for kinematic constraint and the minimal number of active cables for the full control of a movable platform in two rotational DOFs. For a certain geometry of the wrist, the workspace is analyzed using the structure matrix. To control the motion of the wrist, the use of an inertial measurement unit is proposed to directly estimate the orientation and angular velocity, contrarily to the majority of previous cable-driven mechanisms whose control relies on the forward kinematics. Based on the measured data, a standard cascaded controller calculates target torques about two fixed axes of rotation, which are converted into target tensions for the three active cables by the existing closed-form solution. The proposed concept is validated with a hardware prototype. A quasi-static experiment shows that the wrist covers a workspace of up to 55 about both rotation axes. Highly dynamic rotations are demonstrated by step responses with an angular velocity of up to 700/s.<br
Keywords: Wrist; Robots; Torque; Actuators; Topology; Dynamics; Kinematics

Highly efficient and flexible plasma based copper coating process for the manufacture of direct metallized mechatronic devices - Müller, Martin; Franke, Jörg (Proceedings of the 2016 IEEE 18th Electronics Packaging Technology Conference, EPTC 2016, 2017)
The plasma based copper coating process is an innovative process for the production of planar or three dimensional circuit carriers. Both conductor lines for logic circuits and conductors for high power transmissions can be realized. This paper describes the manufacturing process chain of direct metallization by plasma based copper coating and shows the potentials of this technology. Circuits can be applied to almost any base substrate such as polymers, ceramics or even metal since an insulating dielectric lacquer layer separates the substrate from the metallization. In contrast to previous plasma based copper depositing processes the digital direct metallization enables clearly defined fine structures without using any inflexible and high-maintenance masks [1]. An enormous advantage of this procedure is the complete elimination of wet chemical process steps, which are known from the laser direct structuring method (LDS) [2]. In addition to diverse characterizations this paper represents the opportunities of the technology by means of demonstrator applications.
CRIS-Team Scopus Importer:2023-03-07

Highly Efficient Control System Enabling Robot Accuracy Improvement - Buschhaus, Arnd; Blank, Andreas; Ziegler, Christian; Franke, Jörg (5th CATS 2014 - CIRP Conference on Assembly Technologies and Systems, 2014)
The developed control system utilizes existing network technologies and uses data of sensor systems for continuous process monitoring to derive the robots actual state in course of its movement. In case of a high speed camera the image data is acquired by the control system via a first thread and subsequently the actual robot position is calculated based on this data. At the same time, for determining the robots target state, the system continuously requests the robots nominal position from the robot controller by utilizing a parallel second thread. The information describing the robots actual state is then compared with the sensor data for calculating offset values. These offset values are subsequently filtered and a correction value is calculated. In a third parallel thread new movement instructions are generated, considering the offset values as well as the robots target trajectory. Finally, for remote control of the robot, these movement instructions are transferred to the robot controller. (C) 2014 Elsevier B.V.
Keywords: Industrial Robot; Control System; Accuracy Improvement

Highly efficient packaging processes by reactive multilayer materials for die-attach in power electronic applications - Müller, Martin; Franke, Jörg (Proceedings of the 16th Electronics Packaging Technology Conference, EPTC 2014, 2014)
In the field of power electronics, assembly and interconnection technologies play an important role for the design of modules and systems. The applied packaging technologies largely determine the electrical, thermal, and mechanical properties of the final module. In addition to conventional solder technology upcoming technologies like sintering, transient liquid phase soldering or adhesive bonding are interesting methods for the realization of the semiconductor die attach. However, all these technologies imply a costly and time-consuming process chain. An innovative alternative for die attach is represented by reactive multilayer foils, which are a class of nano-engineered materials, to realize the interconnection to the substrate. By applying reactive multilayers for interconnection of electronic components on circuit carriers there is an immense potential to shorten and simplify the process chain of assembly significantly. For example, solder paste printing processes and time-consuming reflow soldering or sintering processes can be completely eliminated. The aim is to realize the application process highly efficient with standard equipment. Therefore a completely integrated placement process is provided. However, an adequately qualification of the reactive multilayer foil as interconnection medium is necessary. From there the mechanical properties of the resulting joints are characterized in this paper.
CRIS-Team Scopus Importer:2023-03-07

High performance accelerated test methods for reliability and life time analyses of power electronic packages - Müller, Martin; Franke, Jörg (Proceedings of the Electronic Packaging Technology Conference, EPTC, 2016)
This paper describes and discusses two methods, with which highly accelerated aging tests on power electronics components can be done efficiently and with high performance. On the one hand, an alternative method of thermal shock tests with a liquid ambient medium is described. By the use of liquids as an energy transfer medium with a high heat transfer coefficient, a quick coupling of thermo-mechanical stresses at the interface of the module can be realized. So the test speed increases and the time of testing decreases. Thereby there is a shock load on the assembly even at low temperature amplitudes. In addition, a liquid-based shock system is characterized by high resource efficiency. In order to avoid any spread of the liquid medium through the transfer process of the test samples, the use of the same medium for the cold and the hot reservoir is required. In recent tests Galden® PFPE D02TS with an application range from -97 °C to +165 °C or the silicone oil WACKER® AK 35 with a maximum operating range from -60 °C to +150 °C are identified as the technically most purposeful liquids. This paper also presents a modified power cycling test equipment, with which the thermal and electrical connection of the device under test with different body variants can be realized flexibly. Further up to 20 samples can be tested simultaneously.
CRIS-Team Scopus Importer:2023-03-07

High-precision assembly of electronic devices with lightweight robots through sensor-guided insertion - Metzner, Maximilian; Leurer, Sebastian; Handwerker, Andreas; Karlidag, Engin; Blank, Andreas; Hefner, Florian; Franke, Jörg (Procedia CIRP, 2020)
Through-hole devices still play an important role in power electronics production. Due to a high number of variants in this field, an automated placement by special machines is often not economically feasible. The resulting manual process is characterized by monotony, ergonomic strain and high labor cost. As a result, a partial automation, using lightweight robots in hybrid assembly system, yields high potential. The lower stiffness and resulting accuracy deficiency of lightweight robots compared to common industrial robots, combined with the precision requirements and inherent fragility of the devices, prohibits the deployment of such systems. In this contribution, a scalable setup and strategies for visual and force-torque guided tactile insertion of such devices is presented and evaluated. A library, based on a system for the offline-programming of such tasks, is used to decrease implementation efforts. A performance evaluation of the system on printed circuit boards with multiple different devices is conducted.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Electronics production; Lightweight robots; Offline programming; Peg in Hole

High Temperature Die Attach: Study and Power Cycling of Direct-Bonded Silver Joints - Häußler, Felix; Sippel, Marcel; Sprenger, Mario; Liu, Lu; Muckelbauer, Martin; Franke, Jörg (2022 IEEE 9th Electronics System-Integration Technology Conference (ESTC), 2022)
Silver direct bonding as die-attach method is a new approach to form metallurgical bonds between dies and copper-ceramic substrates. Silver as a mono-metallic joining partner is a prerequisite and joined by applying pressure and heat for a given time. The aim of this work is to compare electroless and electroplated silver metallization of copper ceramic substrates applicability for direct bonding. This is achieved by comparing shear strength and durability in active power cycling of the formed joints. For the active power cycling the direct bonded samples are compared to sintered interconnects in the same setup. Results show, that the electroplated metallization performs mechanically slightly more stable than the electroless ones but is significantly influenced by surface roughness. The active power cycling results yield the highest reliability for silver sintered bonds in the raw data after power cycling and for the electroplated joints if a junction temperature correction is applied. The reliable electroplated samples reached the failure criteria at a comparable average number of power cycles as the sintered reference samples. Both groups exhibit bond wire lift-off on the topside interconnect as failure cause. Electroless plating reached less than 10,000 cycles in average compared to 35,000 cycles for sintered and 27,000 cycles for electroplated diodes.<br

High temperature thermal cycling reliability of silver sintered and electroplated tin based transient liquid phase joints - Hamilton, Dean P.; Syed Khaja, Aarief Hussain; Franke, Jörg; Mawby, Philip (CIPS 2016 - 9th International Conference on Integrated Power Electronics Systems, 2019)
The long-term reliability of a large range of candidate die attach materials for use in thermal cycled applications in SiC-based high temperature power modules up to a peak temperature of 350°C have been evaluated and tested. These include various types of silver sinter materials in film and paste forms, and transient liquid phase (TLP) joints using tin preforms and electroplated tin, bonded with and without pressure. The silver sinter joint lifetimes have ranged from 104 to 504 x 0-350°C passive thermal cycles to date and all TLP joints have reached 504 cycles to date without shear test failures. Our silver sinter failure analysis have indicated a time and initial densification-dependent coarsening of the microstructure and aggregation of pores at the die attach interface during thermal cycling, eventually leading to a weak die attachment. Although initial TLP bonds using tin preforms gave good thermal cycling results, process issues led to unsatisfactory voiding of the TLP joints and significant fracturing between these voids after cycling. A new process also using electroplated tin instead of pre-forms has been used to produce much improved joints and work is now underway to determine their relative thermal cycling lifetimes.
CRIS-Team Scopus Importer:2019-10-22
Keywords: High temperature; Power modules; Reliability; SiC MOSFETs; Silver sintering; Thermal cycling lifetime; TLP; Transient liquid phase soldering

Holistic Approach to Reducing CO2 Emissions along the Energy-Chain (E-Chain) - Bornschlegl, Martin; Drechsel, Michael; Kreitlein, Sven; Franke, Jörg (Proceedings of the 5th International Conference (ICSAT) 2013, 2013)
Due to the increasing awareness to reduce CO2 emissions, it is important that car producers (OEM) get transparency about their energy consumption. Especially the production emission is becoming a focus topic in the next years. Hence, it should be started to minimize the energy consumption in a sustainable way. Therefore, this chapter presents a new approach to design a sustainable Energy Chain, which considers all elements beginning from the energy supplier to the end customer. Additionally the energy consumption is assessed, whether it is value-adding or not. This helps to find the levers to reduce energy consumption without reducing the level of quality and quantity. For the implementation of the Energy Chain a suitable software architecture is necessary. This chapter shows possible software modules for energy planning.

Holistic production analysis for actuator manufacturing using data mining - Sand, Christian; Bogus, Kim; Kunz, Sabrina; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Holistic production optimizations within large-scale productions are not yet used because classic methods like Six Sigma or DoE are less expedient when it comes to huge or more complex data sets. Thus no standardized analysis for integrated production optimization exists, to realize 0 ppm defects. This paper introduces a holistic analytics approach using data mining techniques to reduce the error and scrap rate, addressing experts and non-specialized workers.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Actuator; Data Mining; Optimization; Tool Wear

Hot crimping through innovative inductive heating in the production of electric motors - Kühl, Alexander; Zitzelsberger, Maximilian; Seefried, Johannes; Masuch, Michael; Miller, Tim; Franke, Jörg (2019 IEEE International Electric Machines and Drives Conference, IEMDC 2019, 2019)
In electrical machine production, the coil ends of the winding must be electrical contacted in the correct phase. The hot-crimping process is a commonly used method for joining the enameled copper wires to a cable lug in one process step. However, due to its working principle, this technology has the strong disadvantage of high tool wear, which leads to frequent maintenance. In this paper, an improved hot crimping method is presented to overcome this detriment. Therefore, inductive heating is used to strip the wires and the tools for crimping are made of a nonconductive technical ceramic.
CRIS-Team Scopus Importer:2019-08-30
Keywords: Contacting; Electric drives production; Hot crimping; Inductive stripping; Winding

Hot Pin Pull Method - New Test Procedure for the Adhesion Measurement for 3D-MID - Goth, Christian; Kuhn, Thomas; Gion, Gerald; Franke, Jörg (11th International Congress Molded Interconnect Devices, 2014)
The adhesion test of metallic structures on MID (Molded Interconnect Devices) parts is an unsolved issue. So far no method really works reliably. The test methods which are conventionally used are the pull-off test and the shear-test. Both show large standard deviation and the reproducibility is not assured. Nordson DAGE has introduced the new micro-material testing system 4000Plus. This device enables a new test method for the determination of the adhesion strength of MID structures using the hot pin pull (hot bump pull) method. Copper pins (tinned or untinned) are heated up with a user defined temperature profile, soldered to a metallized structure on the MID and then removed vertically upward, while the force is recorded. In this contribution investigations with this new test method are presented.
Keywords: 3D-MID; E|P; Elektronikproduktion; Zuverlässigkeit

Human Detection and Gesture Recognition for the Navigation of Unmanned Aircraft - Lieret, Markus; Hübner, Maximilian; Hofmann, Christian; Franke, Jörg (PROCEEDINGS OF THE 17TH INTERNATIONAL JOINT CONFERENCE ON COMPUTER VISION, IMAGING AND COMPUTER GRAPHICS THEORY AND APPLICATIONS (VISAPP), VOL 4, 2022)
CRIS-Team WoS Importer:2022-05-06

“Human-In-The-Loop”- Virtual Commissioning of Human-Robot Collaboration Systems - Metzner, Maximilian; Bönig, Jochen; Blank, Andreas; Schäffer, Eike; Franke, Jörg (Tagungsband des 3. Kongresses Montage Handhabung Industrieroboter, 2018)
Human-robot collaboration (HRC) has the potential to increase the degree of automation, and thus productivity, throughout many industries. However, complex safety considerations and a lack of appropriate planning tools still prohibit a more widespread application. In this paper, the use of virtual commissioning (VC), an established tool for the validation of common automated systems, for the validation of HRC-systems is proposed. For this, the structure of a traditional VC environment is combined with a digital human model (DHM). To ensure adequate behavioral fidelity, a real-time overlay of human action and the virtual automated system, using motion capture technology, is imperative. This also requires the live visualization of the simulation environment via virtual reality (VR). The structure of such a simulation system is presented and evaluated. Furthermore, the cost and benefit for this new method is contrasted.
Keywords: Mensch Roboter Kollaboration; Robotik; Virtuelle Inbetriebnahme; Digitale Menschmodellierung; Motion Capturing; Human-Robot Collaboration; Virtual Commissioning; Digital Human Modeling; Motion Capturing

Human-robot-interaction using cloud-based speech recognition systems - Deuerlein, Christian; Langer, Moritz; Seßner, Julian; Heß, Peter; Franke, Jörg (Procedia CIRP, 2020)
Progress in natural speech processing has enabled significantly more powerful speech processing systems, primarily due to the use of machine learning technologies. In order to integrate cloud-based speech recognition systems for human-robot interaction, an interface for the voice control of a lightweight robot was developed. The main contribution of this work is the design and implementation of a software interface to recognize commands via cloud-based speech processing and the subsequently conversion into machine-readable code. Requirements for the evaluation of different cloud-services for the control of robots are determined. Furthermore, the control architecture for the robot is modeled and implemented. An example application, which enables users to control robot movements via speech, is realized as a proof of concept and for additional studies. This application includes the basic features of cloud-based speech processing: intent recognition from utterances, slot filling and dialogue-based interaction. Lastly, the influence of background noise on process safety was examined within an experiment. It turns out that a feasible process reliability can be achieved with the system despite the presence of background noises.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Cloud-service; Human-robot-interaction; Industrial robot; Speech control

Hybrid Environment Reconstruction Improving User Experience and Workload in Augmented Virtuality Teleoperation - Blank, Andreas; Kosar, Emir; Karlidag, Engin; Guo, Qiang; Kohn, Sebastian; Sommer, Oliver; Walter, Jonas; Herbert, Meike; Seßner, Julian; Querfurth, Frank; Metzner, Maximilian; Franke, Jörg (Procedia Manufacturing, 2021)
Concurrent with autonomous robots, teleoperation gains importance in industrial applications. This includes remote intervention scenarios and human-robot-cooperation during complex or harmful tasks operated from a distance. For an efficient teleoperation, an interface achieving a good user experience and relieving workload of the operators is decisive. Whereas virtual reality allows a spatial integration, environment reconstruction is often based on point clouds in combination with pre-known object models. Challenges exist in spatial representation, through bandwidth limitations and sensor interferences. Furthermore, the potential of knowledge augmentation for workload improvement is often not fully utilized. To overcome these challenges, we present a hybrid environment reconstruction method, which is adaptive regarding the integration of different data sources as well as their derived semantic information levels. For evaluation, a user study is performed. Thereby known procedures to measure usability, immersion, user experience and operator workload serve for evaluation and comparison.<br
Keywords: Teleoperation; Virtual Reality; Environment Reconstruction; Knowledge Augmentation; Human-in-the-Loop

Hydrodynamic lubrication analysis of hydrophobic textured journal bearing considering cavitation - Tauviqirrahman, Mohammad; Jamari,; Muchammad,; Ardiansyah, Azis; Setyana, Budi; Paryanto, Paryanto (Cogent Engineering, 2022)
Lubricated contact performance can be improved by using a textured surface as well as a hydrophobic surface. A procedure to obtain the optimal partially textured journal bearing combined with the hydrophobic coating is presented through the computational fluid dynamics (CFD) codes. In this study, lubricated hydrophobic textured contacts with and without cavitation modeling are discussed. The cavitation phenomena in the lubricant is modeled using a multiphase model of "mixture" to obtain a realistic condition. The effect of dimple depth, as well as the eccentricity ratio, on the tribological performance, is of particular interest. It is found that the tribological performance is greatly influenced by the multiphase flow cavitation scheme. When cavitation modeling is taken into account, higher load support is noted. Furthermore, the simulation results show that a hydrophobic textured surface with a shallow depth (d/h (min)<1) seems to be better for enhancing the tribological performance. Meanwhile, for the case of the low eccentricity ratio, there is an optimal dimple depth giving the highest load support. The findings explored in this work can be considered as a theoretical basis to increase the performance of hydrophobic textured journal bearing.
CRIS-Team WoS Importer:2022-06-10

I4.0-compliant integration of assets utilizing the Asset Administration Shell - Fuchs, Jonathan; Schmidt, Jan; Franke, Jörg; Rehman, Kasim; Karnouskos, Stamatis; Sauer, Manuel (2019 24th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA), 2019)
Global trends such as mass customization and lot size one, demand flexibility, autonomy and adaptability in production. Interoperability of devices is a key challenge as production systems evolve into Cyber-Physical Production Systems (CPPS). As part of the German strategic project Industrie 4.0 (I4.0), concepts and solutions for continuous digitization of production are being developed, in order to meet these numerous challenges. The concept of the Asset Administration Shell (AAS) was introduced in order to provide data and information in a standardized and semantically described manner, thus enabling interoperability and easy interaction. In this paper, we show how users can translate a semantic description of plants, machines or individual components that are based on a standardized Open Platform Communication Unified Architecture (OPC UA) information model, into the AAS information model.<br

Identification of demand side management potentials within the sector of domestic living - Bürner, Johannes; Praß, Julian; Franke, Jörg (Environment and Energy in Bavaria, 2018)

Identification of energy consumption and energy saving potentials of electric drive systems - Javied, Tallal; Kreitlein, Sven; Esfandyari, Alireza; Franke, Jörg (Applied Mechanics and Materials, 2014)
This paper provides an overview of different types of motor systems and several measurement principals in order to determine the electricity usage of these motors. It focuses on the measurement of electric values of different drive systems. A concept of rough analysis using software or excel based tools is discussed, which argues that it is a lot easier, efficient, and cost effective to first pin point the main electricity consumers and then initiate a fine analysis of these selected systems before a cost and time intensive process of measuring every single drive system is undertaken. To achieve this, a simple and systematic process is illustrated in this paper, which can be used to identify the energy saving potential of drive systems without requiring expensive hardware.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficiency; Energy management; Energy measurement

Identifikation, Analyse und Klassifizierung innovativer Geschäftsmodelle der Digitalisierung - Bogner, Eva; Körner, Niklas; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2016)
Innovative Geschäftsmodelle ermöglichen es, neue Chancen zu nutzen und nachhaltigen Erfolg sicherzustellen. Eine Analyse der produzierenden Industrie anhand von Geschäftsmodellmustern zeigt, dass es vor allem spezifische Kombinationen einzelner Muster gibt, die von den untersuchten Unternehmen erfolgsversprechend eingesetzt werden und zu einer deutlichen Abhebung gegenüber dem Wettbewerb führen
Keywords: Geschäftsmodell; Geschäftsmodellinnovation; Industrie 4.0; Digitalisierung

Identifikation von Lastmanagementpotenzialen im Umfeld des privaten Wohnens - Bürner, Johannes; Praß, Julian; Franke, Jörg (Umwelt-Technologie und Energie in Bayern, 2018)

Identifying Agile Roles in Software Engineering Projects using Repository and Work-Tracking Data - Martens, Benedikt; Franke, Jörg (Proceedings of 2022 International Conference on Data and Software Engineering, ICoDSE 2022, 2022)
Software development at corporate scale is a collaborative effort requiring the involvement of people with different responsibilities. In agile software engineering approaches like SCRUM, responsibilities are divided along two main axes. Team membership sets the scope of a group of engineers, defining the parts of the software or types of challenges the individual approaches. Roles define the contribution of the individual within the team. As team and role data are not necessarily defined in the analyzed repository and work-tracking systems, their prediction from available data is beneficial for the understanding of processes and the providing of stakeholder-focused insights based on data. In this paper, we show that data gathered from software repositories and work-tracking systems can be used to predict the role of persons within these systems using machine learning, achieving an accuracy of around 83 percent. We also show how the process definition, specifically the work item hierarchy of the analyzed system is reflected in the analyzed data.
CRIS-Team Scopus Importer:2023-03-07
Keywords: repository mining; software artifacts; software life cycle; software roles

Identifying failure root causes by visualizing parameter interdependencies with spectrograms - Baier, Lukas; Frommherz, Julian; Nöth, Elmar; Donhauser, Toni; Schuderer, Peter; Franke, Jörg (Journal of Manufacturing Systems, 2019)
Fast identification of failure root causes is a major task in minimizing rejects in manufacturing. Due to increasing complexity of products and supply chains many interdependencies affect the final product quality. As knowledge about every possible interdependence is hardly held by individuals, data analysis strategies are required to evaluate captured information. Hence, we propose a root cause identification method for determining the main influencing factors on end products failing end of line tests. Additionally, graphical representation of calculation results in spectrograms similar to audio signals facilitates human interpretation. The evaluation of the proposed method on the basis of a use case proves the applicability in a real scenario. The method is able to identify the root cause for rejects within short periods of time. In this specific case it shortened the analysis time by a factor of about 50. In the future, it empowers smart production systems to automatically identify failure root causes and to take countermeasures like adjusting process parameters.<br
Keywords: Quality management; Root cause analysis; Scrap reduction; Visual management

Impact of Aluminum Metallization Reconstruction on the Current Distribution in Power Semiconductors - Sippel, Marcel; Hassel, Simon; Schmidt, Ralf; Sprenger, Mario; Hecht, Christoph; Franke, Jörg (2022 IEEE 9th Electronics System-Integration Technology Conference, ESTC 2022 - Proceedings, 2022)
For optimized performance of the semiconductor switch in a power electronic module a uniform current distribution in the active volume of the chip is desirable. Since the bottom side of the semiconductor die is fully connected to a substrate by a soldered or even a sintered layer, the vertical current distribution is mainly determined by the top side interconnection technology and the ability of the top side aluminum metallization to spread the current in lateral direction. The focus of this paper is on the influence of the metallization and the top side connection, realized by heavy wire bonds. Sheet resistance and roughness measurements were taken on power modules, aged by active power cycling, in order to evaluate degradation during regular operation. Voltage mapping measurements across the metallization layer during operation were correlated to finite element simulation results, revealing inhomogeneities in the current density distribution in the metallization layer as well as the semiconductor die.
Created from Fastlane, Scopus look-up
Keywords: current density; degradation; metallization; power electronics; reliability

Impact of Electric Vehicle Charging Behavior on the Transmission System and the Electricity Market in Germany - Teske, Franz; Funk, Felix; Fehrle, Adrian; Franke, Jörg (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
The increasing market penetration of electric vehicles (EVs) not only creates challenges at the lower voltage levels of the power grid but also significantly impacts the national energy system. The latter effect is, however, rarely discussed in current research, which primarily focuses on the integration of EVs into the distribution grid. This paper, therefore, examines the impact of defined EV penetration levels and user behaviors on the national transmission grid and wholesale electricity prices. For this purpose, a fundamental model of the German power system, consisting of the loads, the power plants, and the transmission grid, is created. This model is then used to simulate and analyze the impact of selected charging behaviors. It is shown that wholesale electricity prices and transmission grid utilization hardly depend on the chosen hourly charging profile of EVs. Rather, the maximum power and the amount of electricity are the most significant influences. Additional load leads to a small increase in the electricity price, but not to an aggravation of line congestion problems.
CRIS-Team Scopus Importer:2023-03-07
Keywords: charging stations; grid impact; power generation economics; power grids; power markets; transmission grid

Impact of Surface Roughness on 3D printed SLS Horn Antennas - Lomakin, Konstantin; Pavlenko, Tatiana; Sippel, Mark; Gold, Gerald; Helmreich, Klaus; Ankenbrand, Markus; Urban, N; Franke, A (European Conference on Antennas and Propagation (EUCAP), 2018)

Impact of the needle winding technology on the operational behavior of an asynchronous machine - Stenzel, P.; Richnow, J.; Franke, Jörg; Endisch, C. (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
Distributed round-wire windings are usually manufactured using the insertion technology. If the needle winding technology is applied instead the end windings have to be conducted in a three-layer axial arrangement. This leads to differing coil lengths and thus to a phase asymmetry which is much more distinct than the one resulting from the insertion technology. In addition, it is possible that the first phase exhibits a higher end winding leakage inductance than the other phases if the distance between the first phase and the front end side of the stator core is too short. In this case the magnetic flux lines of the end windings partially close across the stator core producing an increase of the end winding leakage inductance. Therefore, in this paper the impact of the needle winding technology on the operational behavior of an asynchronous machine is investigated. For this purpose a needle wound electrical machine with three-layer end windings is compared to an electrical machine with very symmetric windings built up using manual insertion. By the use of the no load and blocked rotor test as well as a static stator measurement the machine parameters are determined and the impact of the phase asymmetry is investigated. In addition, load measurements are conducted in order to quantify the impact of the production related differences.
CRIS-Team Scopus Importer:2023-03-07

Impact of THT-hole dimensioning on manufacturability in selective wave soldering - Seidel, Reinhardt; Ockel, Manuela; Franke, Jörg; Kästle, Christopher (Microelectronics Reliability, 2022)
Higher functional integration and increased electrical and reliability requirements are leading to increasingly complex printed circuit board (PCB) designs. Highly integrated PCBs with mixed SMT/THT assembly cause difficulties in soldering processes due to the thermal mismatch between heat demand and heat supply during soldering and the limited accessibility of THT-solder joints. This directly affects the manufacturability and robustness of the THT-soldering process with respect to sufficient hole fill according to typical quality standards like IPC-A-610. Partial hole fill also affects the mechanical reliability and fatigue resistance of a solder joint as well as its current carrying capacity and high frequency behavior. In the literature, several publications show the positive correlation between a larger hole diameter and vertical hole filling. In this paper, the fundamental relationships between hole diameter, hole filling and process robustness are investigated using design of experiments (DoE). It is shown that hole filling increases with increasing hole diameter, while keeping all other parameters constant. It was found that the process also becomes more robust at shorter solder contact times and lowers preheat temperatures. From these results, a general recommendation for larger THT holes in selective wave soldering can be derived. This is consistent with several other literature reports. In contrast to previous publications, it is not only shown how increasing the gap favors hole filling, but also what this means for the robustness of the soldering process to different PCB copper layer designs and soldering parameters. In addition, the impact of hole diameter is evaluated with respect to robotic component placement and back-end processes such as testing. A Gap-Ratio of 30–40 % is recommended for selective wave soldering to ensure robust soldering processes.<br

Implementation of an Intralogistics Routing-Service Basing on Decentralized Workspace Digitization - Scholz, Michael; Zhang, Xu; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production IV, 2018)

Implementation of a Scattering Method for Rough Surfaces in a Raytracing Software linked with a CAD (Computer-Aided Design) Toolbox - Loosen, Florian; Backhaus, Carsten; Lindlein, Norbert; Zeitler, Jochen Tobias; Franke, Jörg (Frontiers in Optics 2016, OSA Technical Digest (online) (Optical Society of America, 2016), paper FW3H.2, 2016)
The design and simulation of printed polymer optical waveguides is a new approach in the field of raytracing techniques, to link the CAD routines with the simulation process of the waveguides via raytracing methods.
Keywords: Polymer waveguides (130.5460); Propagating methods (220.2560); Scattering; rough surfaces (290.5880)

Implementation of autonomous and semi-Autonomous mobile systems to operation rooms: A study of nowaday standardization, general conditions and the concept of a constructive concept - Scholz, Michael; Sebner, Julian; Blank, Andreas; Franke, Jörg (IECBES 2016 - IEEE-EMBS Conference on Biomedical Engineering and Sciences, 2016)
This paper addresses the necessity of the implementation of mobile assistant platforms in the medical sector and gives an overview of actual research activities. By transferring autonomous and mobile systems from the industrial sector to the operating room it is possible to improve the therapy and operations in the medical sector and to reduce the workload of the employees. The research work in the industrial sector showed that the routing and pathing of autonomous and semi-Autonomous systems in high variable working areas with infrastructural sensors, like ceiling cameras, has advantages over systems where the sensors for the self-localization and the collision avoidance is mounted to the mobile platform. The main challenge for the transformation of the know-how based on industrial platforms are the special regulations in the medical sector. In combination with a regular medical device, these platforms are also medical devices due to 93/42/EWG. In the second chapter the industrial standardizations and the special medical specifications are addressed. Besides, the whole concept bases on a digitalization of the environment of the mobile platform with ceiling mounted cameras. Due to the different geometrical dimensions of operating rooms to common industrial work areas, a different concept of the angle of view is necessary. The fourth chapter gives an overview of different angles of view and the position of the camera within an operating room regarding two specific medical scenarios. The concept also includes a fine-positioning system with an orthogonal camera mounted on the mobile platform.
CRIS-Team Scopus Importer:2023-03-07
Keywords: digitalization of operation rooms; image processing; mobile medical platforms; semi-Automation of medical devices

Implementation of autonomous and semi-autonomous mobile systems to operation rooms - Scholz, Michael; Seßner, Julian; Blank, Andreas; Franke, Jörg (Biomedical Engineering and Sciences (IECBES), 2016)
This paper addresses the necessity of the implementation of mobile assistant platforms in the medical sector and gives an overview of actual research activities. By transferring autonomous and mobile systems from the industrial sector to the operating room it is possible to improve the therapy and operations in the medical sector and to reduce the workload of the employees. The research work in the industrial sector showed that the routing and pathing of autonomous and semi-autonomous systems in high variable working areas with infrastructural sensors, like ceiling cameras, has advantages over systems where the sensors for the self-localization and the collision avoidance is mounted to the mobile platform. The main challenge for the transformation of the know-how based on industrial platforms are the special regulations in the medical sector. In combination with a regular medical device, these platforms are also medical devices due to 93/42/EWG. In the second chapter the industrial standardizations and the special medical specifications are addressed. Besides, the whole concept bases on a digitalization of the environment of the mobile platform with ceiling mounted cameras. Due to the different geometrical dimensions of operating rooms to common industrial work areas, a different concept of the angle of view is necessary. The fourth chapter gives an overview of different angles of view and the position of the camera within an operating room regarding two specific medical scenarios. The concept also includes a fine-positioning system with an orthogonal camera mounted on the mobile platform.
Keywords: Cameras; Sensors; Mobile communication; Biomedical imaging; Safety; Guidelines

Implementation of Machine Vision based Quality Inspection in Production: An Approach for the Accelerated Execution of Case Studies - Reichenstein, Tobias; Raffin, Tim; Sand, Christian; Franke, Jörg (Procedia CIRP, 2022)
The implementation of machine vision based quality inspection systems increases productivity and reduces human error during visual inspection, thus improving product quality. During the planning process of these inspection systems, case studies are executed to evaluate and ensure applicability, which so far has been an iterative and inefficient process due to the lack of existing methodologies and guidelines. Therefore, this paper presents a holistic approach for efficiently executing case studies to plan and implement machine vision based quality inspection systems in production. An evaluation via an industrial use-case resulted in a significantly quicker planning process.<br

Implementation of the Needle Winding Technique for Diamond Coils - Bickel, Benjamin; Mahr, Alexander; Kühl, Alexander; Franke, Jörg; Meixner, Sebastian; Berendt, Emil; Riedel, Andreas (5th International Electric Drives Production Conference, 2015)

Implementing energy management system to increase energy efficiency in manufacturing companies - Javied, Tallal; Rackow, Tobias; Franke, Jörg (Procedia CIRP, 2015)
One of the main pillars of the modern industry is the uninterrupted supply of energy with a reasonable price. The energy production is based mostly on non-renewable energy resources that are getting more expensive progressively. This increase in energy cost consequently leads the companies to a more expensive production of goods. Therefore it has been established that energy efficiency is not only very important for the environment but also for the sustainable production in the manufacturing companies. Effective energy management plays an important role in the necessary increase of energy efficiency in industry. Next to the expansion of regenerative energies, it establishes a further pillar at closing the energy supply gap resulting from the energy transition. This paper presents the current energy situation in Germany and its impact on the German industry. Furthermore this paper presents a methodology which can be used by organizations to systematically implement energy management system. Eventually the paper provides a model that illustrates the realization of a PDCA cycle which is necessary for energy management in the organization.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficiency; Energy management; Organization structure; Sustainability

Important Parameters of Printed Polymer Optical Waveguides (POWs) in Simulation and Fabrication - Reitberger, Thomas; Franke, Jörg; Loosen, Florian; Lindlein, Norbert (Proc. SPIE 10098, Physics and Simulation of Optoelectronic Devices XXV, 100981B (February 22, 2017), 2017)
In this paper, polymer optical waveguides (POWs), fabricated by using flexographic printing for printing conditioning lines onto polymethylmethacrylate (PMMA) foil substrate material and Aerosol Jet Printing for producing the core and cladding of the waveguide, are characterized by using Monte Carlo raytracing for the scattering process. This method offers the opportunity to simulate the propagation of light, which are traced through the produced POWs. In the first step, the surface roughness of all optical materials, which are involved in the fabrication process of the POWs, are measured. The roughness measurement of substrate, core and cladding material is necessary to interlink the surface roughness (Monte Carlo scattering model) with a non-sequential raytracing method. Not only the surface of each material is investigated, but also the roughness measurement of the interlayer between the printed core and cladding material is examined. To build up the complete manufacturing technology virtually, also the process parameters of the printing need to be investigated. The results of the tracing must be a value of the attenuation of a simulated printed POW to give the designer a feedback about the optical quality of the waveguide before the printing process. This project is part of the DFG (the German Research Foundation) founded research group OPTAVER where the goal is to build up the whole manufacturing process, from the CAD, over the simulation, to the fabrication process and coupling of such printed POWs. © (2017) COPYRIGHT Society of Photo-Optical Instrumentation Engineers (SPIE). Downloading of the abstract is permitted for personal use only.
Keywords: Fabrication; Polymers; Simulations; Waveguides; Printing; Cladding; Scattering; Surface roughness; Manufacturing; Optical materials

Improved design flexibility of open robot cells through tool-center-point monitoring - Deuerlein, Christian; Müller, Fabian; Seßner, Julian; Heß, Peter; Franke, Jörg (Procedia CIRP, 2021)
The development of sensitive robots is also accompanied by the implementation of open cell concepts. Contrary to the classic safety of robotic cells, separating protective barriers can be avoided with these concepts. For design engineers, this results in an increased design flexibility for the layout of robot cells. This paper addresses the disadvantages of open cell concepts and presents a method for real-time monitoring of end effectors of industrial robots. The method uses a sensor module at the robot's flange to produce a reference record of distance values within the cell of the process. The recorded sensor data is compared with incoming sensor signals. This enables very short calculation times to evaluate the safety and thus minimizes the required safety distances. The validation of the concept is done by means of a simulation on the detection rate of the sensor module. Within the experiments an accuracy of about 87 % with a single shot data point could be achieved.
CRIS-Team Scopus Importer:2021-08-13
Keywords: Industrial Robots; Open Cell Design; Safety

Improved thermal behavior of an electromagnetic linear actuator with different winding types and the influence on the complex impedance - Reissenweber, Lukas; Stadler, Alexander; von Lindenfels, Johannes; Franke, Jörg (2019 9th International Electric Drives Production Conference, EDPC 2019 - Proceedings, 2019)
Using the example of an existing linear actuator, the advantages and disadvantages of a winding body made of aluminum with aluminum oxide as insulation in comparison to a winding body made of coated copper wire are investigated. The increase in the maximum current load (increased force effect) is achieved by an improved thermal heat dissipation of the resistive losses. If the force effect is to be maintained, the increase of the current can reduce the number of windings and thus also the material and installation space. Although the coil made of aluminum is subject to higher losses due to the lower electrical conductivity of aluminum compared to copper, these losses can be better dissipated from the actuator due to the thermal conductivity of the oxide layer. The thermal conductivity of the oxide layer is about 140 times higher compared to epoxy insulation that a significant reduction in the hot spot temperature is achieved. At the same time, the winding body can be subjected to significantly higher temperatures, which enables a further reduction in installation space. In addition, the low layer thickness of aluminum oxide allows a higher filling factor (more compact design). Together with the 3 times higher permittivity of aluminum oxide compared to epoxy, this has significant effect on the effective capacities as well as the resistance and thus on electric behavior. This is the second focus of the work. The influence of the different coil concepts on the complex impedance is analyzed. Therefore analytical calculations are combined with detailed axial symmetrical FEM simulations.
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Keywords: Aluminum winding; Complex impedance; Electromagnetic analysis; Solenoid actuator; Thermal simulation

Improved Thermal Impedance Measurement for Power Modules based on Thermal Imaging of the Baseplate - Sippel, Marcel; Schmidt, Ralf; Rau, Fabian; Bretscher, Daniel; Seidel, Reinhardt; Franke, Jörg (Proceedings of the 12th International Conference on Integrated Power Electronics Systems (CIPS 2022), 2022)

Improving maintenance processes with distributed monitoring systems - Fleischmann, Hans; Kohl, Johannes; Franke, Jörg; Reidt, Andreas; Duchon, Markus; Krcmar, Helmut (IEEE International Conference on Industrial Informatics (INDIN), 2016)
Industrial production systems meet strict requirements regarding availability, process control and condition monitoring. As a key enabler of Industry 4.0, cyber-physical systems form the core of a modular, web-based framework, which delivers more efficient condition monitoring mechanisms for maintenance staff in production facilities. The present approach illustrates the potential of a decentralized and centralized, distributed system by using standardized communication protocols and semantic information models. The use of web-based platforms like node.js and protocols such as OPC UA offers the ability to automate transferring information about anomalies, root causes and nominal data directly between cloud-based services and condition monitoring systems on the shop floor. To conclude, a validation is accomplished within a case study on a flexible handling unit.
CRIS-Team Scopus Importer:2023-03-07

Improving partial wetting resolution on flexible substrates for application of polymer optical waveguides - Hoffmann, Gerd-Albert; Wolfer, Tim; Reitberger, Thomas; Franke, Jörg; Suttmann, Oliver; Overmeyer, Ludger (Optical Engineering, 2017)
Considering the increasing amount of data for communication and infotainment applications, fabrication of optical networks and bus systems is a challenging task for production engineering. A two-step manufacturing process for polymer optical waveguides is presented. By improving the highly efficient flexographic printing technology by laser functionalization of the printing tool in combination with a subsequent spray application, high-quality waveguides are accomplished. By adjusting the resulting surface energy of the foil substrate in the first fabrication process, the spray application achieved high-aspect ratio waveguides with a low attenuation of 0.2 dB/cm at 850 nm.
CRIS-Team Scopus Importer:2023-03-07
Keywords: flexographic printing; laser functionalizing; partial wetting; polymer optical waveguides

Improving the energy efficiency of industrial drying processes: a computational fluid dynamics approach - Hoffmann, Christoph; Praß, Julian; Uhlemann, Thomas; Franke, Jörg (Procedia Manufacturing, 2019)
Keywords: computational fluid dynamics; sustainable manufacturing; industrial drying processes; energy efficiency; residual moisture; drying after electroplating

Improving the Inductive Crimping Technology in the Production of Electric Motors - Kühl, Alexander; Franke, Jörg (2021 IEEE SIXTY-SIXTH HOLM CONFERENCE ON ELECTRICAL CONTACTS (HLM), 2021)
CRIS-Team WoS Importer:2022-05-13

Improving the integrated fabrication of insulation systems in electric drives by injection molding of thermosets due to processing conditions and slot design - Rösel, Uta; Kneidl, Maximilian; Franke, Jörg; Drummer, Dietmar (Polymers, 2023)
The expanding demand for electro mobility in general and specifically for electrified vehicles requires the expansion of electro mobility technology with respect to variations in the requirements of the process and the application. Within the stator, the electrical insulation system has a high impact on the application properties. So far, limitations, such as the identification of suitable materials for the stator insulation or high costs in the processes, have hindered the implementation of new applications. Therefore, a new technology that allows integrated fabrication via the injection molding of thermosets is founded in order to expand the applications of stators. The possibility of the integrated fabrication of insulation systems to meet the demands of the application can be improved by the processing conditions and the slot design. Within this paper, two epoxy (EP) types with different fillers are investigated to show the impact of the fabrication process in terms of different parameters; these include the holding pressure or the temperature setup, as well as the slot design and with that the flow conditions. To evaluate the improvement in the insulation system of electric drives, a single slot sample, consisting of two parallel copper wires, was used. Then, the two parameters of the average partial discharge (PD) and the partial discharge extinction voltage (PDEV), as well as the full encapsulation detected by microscopy images, were analyzed. It was shown that both characteristics (electric properties—PD and PDEV; full encapsulation) could be improved in terms of an increase in the holding pressure (up to 600 bar) or a reduction in the heating time (around 40 s), as well as the injection speed (down to 15 mm/s). Further, an improvement in the properties can be reached by increasing the space between the wires, as well as the wire and the stack, due to a higher slot depth or by implementing flow-improving grooves that have a positive effect on the flow conditions. With that, the optimization of the integrated fabrication of insulation systems in electric drives via the injection molding of thermosets was enabled with respect to the process conditions and the slot design.<br
Keywords: thermoset; injection molding; insulation system

Improving the reliability of power modules through layered diffusion solder interconnects – Comparative study based on experiments and FE-simulation - Ottinger, Bettina; Mathew, A.; König, S.; Albrecht, J.; Sprenger, M.; Müller, L.; Goth, C.; Franke, Jörg (Microelectronics Reliability, 2023)
The demand for reliable, lead-free and high temperature stable solder interconnects for power electronic application has increased in recent years. The die attach solder materials are exposed to higher electrical currents and temperatures due to advancing designs and wide band-gap semiconductors. The diffusion soldering material Sn-Cu-Sn with its high post processing melting temperature is a promising option for high temperature die attach interconnects. The aim of this work is to predict potential failure mechanisms in the die attach of automotive power modules due to simulation based thermo-mechanical analysis of the diffusion solder Sn-Cu-Sn layer and SAC. The FE-model is validated with experimental results from active power cycling tests. The simulation indicates a potential for lifetime increase by usage of layered diffusion solder. The created FE-simulation model could be used for simulation-based design for reliability to reduce material costs and development time.<br

Incentive models for electricity customers to participate in a cloud-based energy management system to generate flexibilities - Fehrle, Adrian; Teske, Franz; Franke, Jörg (IEEE PES Innovative Smart Grid Technologies, 2022)
The energy transition poses major challenges to utilities due to the decentralized and volatile feed-in of renewable energies as well as the increasing numbers of electric vehicles. As part of the Cloud|E research project, an intelligent cloud-based energy management system (EMS) is being developed in which flexibility options are made available to the utilities by connecting components for power generation, power storage, and large loads in private households. However, to enable such a cloud-driven EMS, the households need to be motivated to participate in this cloud-based system. For this purpose, three different incentive models are presented in this paper. These models are compared and evaluated with the help of a user acceptance study. The study shows a fundamentally very high willingness to integrate components into a cloud system. At the same time, however, it also reveals a clear difference in the interests of customers according to age group.<br

Increasing charging station availability through peer-to-peer reservation markets - Funk, Felix; Teske, Franz; Fehrle, Adrian; Franke, Jörg (2021 11th International Electric Drives Production Conference (EDPC), 2021)
A key condition for the continued proliferation of electric vehicles (EV) is the availability of EV charging infrastructure. While the expansion of the public network is progressing slowly, the number of private installations of charging stations is growing rapidly. In combination with a rooftop photovoltaic system (PV), private wallboxes provide inexpensive EV charging while simultaneously increasing the level of self-consumption. However, individual charging demand is limited and surplus energy has to be fed into the grid at unfavorable prices, which in addition leads to feed-in peaks that stress the electrical infrastructure. In this work, we hence propose the creation of a public marketplace for private charging capacity. Through this marketplace the availability of charging stations is improved, feed-in peaks in the grid are diminished, and an additional, more profitable revenue stream for PV-owners is created while charging prices are reduced at the same time. We validate the proposition by approximating the market size and estimating the capacity utilization based on real data from a geographically coherent example region.
Keywords: Photovoltaic systems; Production; Charging stations; Electric vehicle charging; Peer-to-peer computing; Stress: Two-sided market; power grids

Increasing Efficiency in Maintenance Processes Through Modular Service Bundles - Fuchs, Jonathan; Herrmann, Hanna; Oks, Sascha Julian; Sjarov, Martin; Franke, Jörg (Production at the leading edge of technology, Proceedings of the 10th Congress of the German Academic Association for Production Technology (WGP), Dresden, 23-24 September 2020, 2021)
Increasing complexity in production and factory automation represents a significant challenge in context of maintenance. One approach to address complexity is the implementation of automated industrial service bundles, which resemble complex business processes. To enable efficient usage of service bundles, their individual components are designed as functional modules in the form of independent micro services and are compatible with the paradigm of service-oriented architectures. For ubiquitous communication and data exchange between service entities, message-oriented middleware provides an adequate solution. This paper presents an approach for increasing efficiency in maintenance using a service bundle. The use case demonstrates the automated creation of service tickets enriched with necessary information from various source
Keywords: Smart services; Service bundle; Smart maintenance; Process automation

Increasing the Automation Degree in Wiring Harness Assembly by Extending the Standard Crimping Machines by Developed Assembly Concept - Heisler, Paul; Hößle, Stefan; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production III, 2017)
In the automotive industry, the assembly of wiring harnesses is done mostly manually. This leads to high labour costs as well as a high number of defects. In order to minimize these disadvantages, both industry and research made huge efforts in recent decades to increase the level of automation in the assembly of wiring harness modules. The fully automated crimping and blockloading machine e.g. Komax Zeta 656, is already successfully used in the industry as a machine for the automated assembly of small wiring harnesses. But still, there is a great potential to increase efficiency and quality in the assembly of wiring harnesses. This paper presents a newly developed machine concept for the fully automated assembly of wiring harnesses. It is shown that the new system can provide higher production efficiency compared to both the competitive systems and manual assembly. The presented concept also helps saving resources as it uses the standard crimping machine as e.g. Komax Alpha 355 as a basis which is already present in many wiring harness factories. To set up the presented mounting machine the Komax Alpha has not to be fully replaced, but only to be extended by a few components.
Keywords: Wiring Harness Production; Automated Wire Handling; Cost Efficient Production

Increasing the energy efficiency of the impulse magnetizing process - Meyer, Alexander Wilhelm; Nolte, Christian; Fischer, Carina; Sauerhofer, Andreas; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Magnetizing rare earth magnets with high coercivity needs strong magnetic fields. To create the necessary field strength, copper coils are used requiring current strengths of several kA. Since the electrical resistance of copper differs from zero, this also means enormous thermal losses. Hence to reduce the losses and to avoid thermal damage of the coil, only short current pulses are applied generated by a pulse magnetizer. However, the efficiency of the process is very poor and lies in the lower per mil range [2]. The presented paper explains the impulse magnetization process in detail with focus on the losses within the magnetization device. Further different material parameters influencing the saturation field strength, such as conductivity, size and diameter to length ratio are presented and possibilities to improve the energy efficiency are shown.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric drive; magnetizer; permanent magnet; pulsed field magnetization; rotor assembly; synchronous mtor

Indicators and countermeasures of modern slavery in global supply chains: Pathway to a social supply chain management framework - Bodendorf, Frank; Wonn, Fabian; Simon, Kristin; Franke, Jörg (Business Strategy and the Environment, 2022)
Even though global supply chains are (usually unintentionally) tied to slave labor, research and practice have largely ignored the issue. This is expected to change as civil society activism and new legislation increase the risk of litigation and reputational damage to supply chain partners. To deal with and combat modern slavery in the supply chain, a theory inspired social supply chain management framework consisting of indicators and countermeasures of modern slavery in the supply chain is developed. The framework is refined in a qualitative expert interview study. The theoretical framework is then evaluated by a multimethod empirical analysis that includes a multicase study based on publicly available supply chain data from 6000 media articles and company websites as well as a quantitative empirical study based on survey data from 280 corporate sustainability experts operating in global supply networks. The results show that economic, political-legal, social, and environmental factors have a significant impact on contemporary slavery in the supply chain. The study also motivates supply chain partners to use preventative and detective measures to reduce the probability of encountering modern slavery actions in their supply chain. Theoretical and managerial implications are drawn from the findings, pointing to a holistic approach to combatting modern slavery in the supply chain.
CRIS-Team WoS Importer:2022-09-23

Induction of anisotropic motions in dielectric elastomer actuators by additive manufacturing - Martin, Sina; Riethmüller, J.; Weigand, C.; Reitelshöfer, Sebastian; Franke, Jörg (Proceedings of SPIE - The International Society for Optical Engineering, 2022)
Dielectric elastomer actuators (DEA) exhibit homogeneous driving behavior due to the incompressible material properties of the homogeneous dielectric. This causes the system to expand uniformly in-plane while decreasing its height. In many applications, however, linear actuation is required and the system must be adjusted to operate unidirectionally. For this purpose, different approaches, such as rolling or mechanical stiffening of the actuator, are presented in literature, which aim at adjusting the DEA to work in one direction. In addition, pre-stretching the elastomer film in the required direction can cause the uniaxial motion. Furthermore, there are reports of interpenetrating networks (IPN) forming an anisotropic network that behaves differently depending on the direction. However, these modifications require either external, usually rigid hardware, or additional manufacturing steps that increase the complexity of the process. In the present work, an anisotropic expansion is introduced by our additive manufacturing technique based on aerosol jet printing. By varying the material distribution and the printing of different patterns, the mechanical and electrical properties are changed, resulting in anisotropic driving behavior. In-plane motion is observed with a camera, and the relationship between longitudinal and transverse strain is evaluated using image processing. Systematic design of experiments (DoE) is used to analyze the influencing factors and determine the most promising system design and achievable aspect ratio.
CRIS-Team Scopus Importer:2022-06-24
Keywords: additive manufacturing; anisotropy; asymmetric expansion; Dielectric elastomer actuators; electrode pattern; heterogeneous electrodes

Industrial Robots Accuracy Optimization in the Area of Structuring and Metallization of Three Dimensional Molded Interconnect Devices - Buschhaus, Arnd; Franke, Jörg (Robotics in Smart Manufacturing, 2013)
Based on their beneficial features, there is a growing importance of three dimensional molded interconnect devices. An important process in course of their manufacturing is the metallization for generating the conducting pattern layout. Therefore, flexible handling devices like industrial robots have to be provided, moving the substrate with a high accuracy relative to a process nozzle. Due to complex three dimensional conducting patterns an offline programming of the robots trajectory is needed. Given to the real robot, this leads to a geometric precision of the movement not meeting the high product demands. To overcome this problem, the usage of modern optical sensor systems for online process monitoring and subsequent real-time robot control is investigated. By continuously supervising the conducting pattern generation the actual robots position is derived. Subsequently, compared to the robots target position, geometric correction values are determined and given to the robot control position deviations can be compensated. For this way of proceeding a highly efficient methodology for image data processing and correction value determination has to be developed. First experiments already show good results with very high geometric accuracies and a very promising data-processing performance.
Keywords: 3D-MID; B|Mech; closed-loop-control; Robotics; sensor systems

Influence of convection sintering parameters on electrical conductivity and adhesion of inkjet-printed silver nanoparticle inks on flexible substrates - Roudenko, Jewgeni; Schirmer, Julian; Reichenberger, Marcus; Neermann, Simone; Franke, Jörg (13th International Congress Molded Interconnect Devices (MID), 2018)

Influence of Current Density on Wire Bond Lifetime in Active Power Cycling Test - Sippel, Marcel; Schmidt, Ralf; Kaesbauer, Michael; Sprenger, Mario; Hensel, Alexander; Franke, Jörg (Electronics Packaging Technology Conference (EPTC), 2022)
The top side interconnection of a power semiconductor by aluminum heavy wire bonds is one key point of failure during operation. State of the art lifetime models mostly focus on the operating conditions of the power module. They can be used to correlate lifetime testing data with application conditions but cannot cover the wide range of design parameters relevant for the development of a power module. An extensive power cycling study was conducted in order to evaluate the additional stress induced in the bond interface on the chip by the wire bond loop, with the main focus being on the load current in the wire bond. A strong correlation between the power loss density in the bond loop and the tested lifetime was found over a wide range of load currents. Additional influence factors, such as the number of stitches, were identified in this study. This data can be used to expand existing lifetime models and make them more relevant for power module design.<br

Influence of cutting edge on core loss induced through various manufacturing parameters - Schneider, Michael; Hubert, Markus; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Various manufacturing processes in the production-from laminated magnetic steel sheets to an assembled stator-affect the electromagnetic characteristics. Often the manufacturing processes of the process step cutting are compared to highlight differences. Many publications have already dealt with this issue over several decades. Flux distribution, loss and the B-H characteristics are not the same, whether an electrical sheet with defined geometry is cut with a laser, water jet, electrical discharge machining, rotational cutting or with a punching machine. It is adequately researched that differences in loss behavior occur. Within the various technologies, a comparison of varied production parameters is scarcer. Here, interesting studies result when considering the specific hysteresis and eddy current losses in the variation of the process parameters on the relative position of the rolling direction, average speed, distance energy and the comparison between fiber and CO2-Laser with different focus diameters. This paper deals with the comparison of cut sheets made from electrical steel with grade M270 35A. The metal strips investigated were prepared on dimensions of 150×150 mm and 37,5×150 mm using the above parameter variation and analyzed in a single sheet tester from Brockhaus regarding their loss behavior.
CRIS-Team Scopus Importer:2023-03-07
Keywords: cutting; iron losses; measurement; sheet metal

Influence of Enameled Wire Preparation on the Laser welding of Hairpin Windings - Gläßel, Tobias; Riedel, Andreas; Franke, Jörg; Kühl, Alexander (2022 IEEE 67TH HOLM CONFERENCE ON ELECTRICAL CONTACTS (HLM), 2022)
CRIS-Team WoS Importer:2023-02-10

Influence of Material and Processing Parameters on the Surface Roughness of Injection-Molded Ceramic Parts - Greiner, Sandra; Kurth, Katharina; Fix, Christine; Braun, Thomas; Franke, Jörg; Drummer, Dietmar (Journal of Ceramic Science and Technology, 2017)

Influence of Melt-Pool Stability in 3D Printing of NdFeB Magnets on Density and Magnetic Properties - Skalon, Mateusz; Görtler, Michael; Meier, Benjamin; Arneitz, Siegfried; Urban, Nikolaus; Mitsche, Stefan; Huber, Christian; Franke, Jörg; Sommitsch, Christof (Materials, 2019)

Influence of the Bond Foot Angle on Active Power Cycling Lifetime of Wire Bonds - Sippel, Marcel; Tan, Yi Fong; Schmidt, Ralf; Botazzoli, Pietro; Sprenger, Mario; Franke, Jörg (2023 24th International Conference on Thermal, Mechanical and Multi-Physics Simulation and Experiments in Microelectronics and Microsystems, EuroSimE 2023, 2023)
The wire bond interconnection on a semiconductor chip is one of the key failure points for standard power electronic modules. Miniaturization efforts as well as additional module components can limit the design options regarding the geometry of the bond loop and the positioning of the bond feet. It can be necessary to deviate from the standard layout with all bond feet positioned along one axis, which results in an angle between the bond foot and the bond loop. The impact of this design parameter was evaluated by means of a power cycling study. It was found that an increase in the bond foot angle resulted in a significant reduction in lifetime for bonds on power semiconductors. For a better understanding of this effect, the strain distribution at the bond interface was evaluated using a multiphysics simulation. An adapted analysis routine for the simulation results was established, which was able to confirm the impact of the bond foot angle and provided a good correlation of the strain at the interface to the tested lifetime of the interconnection.
CRIS-Team Scopus Importer:2023-05-19