Simulation hochautomatisierter Serienproduktion - Produktivitätssteigerung im Ramp-Down - Lechler, Tobias; Zerreis, Maximilian; Sitz, Sarah; Reinhard, Maximilian; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2020)
Der Ramp-Down einer hochautomatisierten Serienproduktion ist mit einer Reihe kostenkritischer Herausforderungen und Planungsunsicherheiten verbunden. Die ereignisdiskrete Materialflusssimulation bietet ein Werkzeug zur Bewältigung dieser Herausforderungen, indem sie mögliche Ramp-Down-Szenarien im Voraus auf Wirtschaftlichkeit prüft und Kosteneinsparungspotenziale aufzeigt. Als Entscheidungsgrundlage kann die Simulation gezielt Fehler verhindern und die Produktivität im Serienauslauf steigern. Die Potenziale eines solchen Vorgehens werden anhand eines Beispiels aus der hochautomatisierten Serienproduktion aufgezeigt.<br
Keywords: Ramp-Down; Ereignisdiskrete Materialflusssimulation; Serienauslauf; Produktionsstrategien

Simulation of laser structuring by three dimensional heat transfer model - Bachy, Bassim; Franke, Jörg (2014 9th International Microsystems, Packaging, Assembly and Circuits Technology Conference: Challenges of Change - Shaping the Future, IMPACT 2014 - Proceedings, 2014)
In this study, a three dimensional numerical heat transfer model has been used to simulate the laser structuring of polymer substrate material in the Three-Dimensional Molded Interconnect Device (3D MID) which is used in the advanced multi-functional applications. A finite element method (FEM) transient thermal analysis is performed using APDL (ANSYS Parametric Design Language) provided by ANSYS. In this model, the effect of surface heat source was modeled with Gaussian distribution, also the effect of the mixed boundary conditions which consist of convection and radiation heat transfers have been considered in this analysis. The model provides a full description of the temperature distribution, as well as calculates the depth and the width of the groove upon material removal at different set of laser parameters such as laser power and laser speed. This study also includes the experimental procedure to study the effect of laser parameters on the depth and width of the removal groove metal as verification to the modeled results. Good agreement between the experimental and the model results is achieved for a wide range of laser powers. It is found that the quality of the laser structure process is affected by the laser scan speed and laser power. For a high laser structured quality, it is suggested to use laser with high speed and moderate to high laser power.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Finite element analysis; Laser Structuring; Simulation; Thermal modeling

Simulation of orthocyclic windings using the linear winding technique - Bönig, Jochen; Bickel, Benjamin; Spahr, Michael; Fischer, Christian; Franke, Jörg (5th International Conference on Electric Drives Production, EDPC 2015, 2015)
A continuously rising number of electric vehicle licensing is mentioned since the last few years in Germany. 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 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. The tool works with an explicit time integration method for time discretization. To represent the high dynamic process of winding within this simulation, 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 non-linear material properties of the wire are validated under scrutiny by a tensile test and by values out of datasheets in previous research work. Simulation results of orthocyclic windings using the linear winding technique are presented within this paper. The dynamic simulation model is validated by experiments using the caster angle of the wire guide as reference parameter. The caster angel rises during the winding process of the first layer until the wire jumps to the next layer. Hence, it is possible to identify the maximum caster angle and match the simulation value against the experiment value. The travel profile of the wire guide is identified as extremely important to generate an orthocyclic winding. Another substantial part is the wire fixation respectively the geometry to support the first winding offset from winding one to winding two. Results of orthocyclic windings are simulated with and without grooves on the coil body surface and demonstrate the positive influence of grooves for an accurate orthocyclic winding picture.
Keywords: Explicit dynamics; linear winding; simulation

Simulation, Optimization and Experimental Verification of the Over-Pressure Reflow Soldering Process - Esfandyari, Alireza; Bachy, Bassim; Raithel, Stefan; Syed Khaja, Aarief Hussain; Franke, Jörg (Procedia CIRP, 2017)
The advanced technologies for electronics production and convection based soldering technologies are growing steadily. The enhanced reflow soldering oven with an integrated hyper pneumatic module ensures a void-free solder connection, but it requires design and installation of the process parameters in the oven in order to ensure optimized heat transfer and derive the best energy efficiency performance. This paper presents a simulation model of the thermal soldering process in the over-pressure convection oven by finite element model. This model considers the effect of the complex boundary conditions during the soldering process. A set of experimental tasks were designed to investigate the variations in the temperature profiles at selected points on the surface of the demonstrator. Moreover, the heat transfer coefficient for each thermal profile has been calculated. The simulation model can be used to predict the temperature distribution for the solder materials together with the demonstrator board. The void content in the solder material was investigated by the X-Ray analysis and correlated with the thermal process in the simulation. Hence, the optimized relation between the process set-up parameters in the oven, simulated thermal behavior, and the voids fraction in solder material are studied in detail.
CRIS-Team Scopus Importer:2023-03-07
Keywords: defect analysis; electronics production; Heat transfer simulation; reflow soldering oven

Simulationsbasierte Optimierung von Fabrikabläufen: Implementierung und Test eines Algorithmus zur ereignisbasierten Regelung der Materialflüsse - Donhauser, T.; Baier, L.; Ebersbach, Tobias; Franke, Jörg; Schuderer, P. (wt Werkstattstechnik - Online, 2018)
Calcium silicate masonry production requires a great deal of planning and control due to the fact that subprocesses vary in terms of process technology and time. To overcome this complexity, a simulation-based optimization approach is applied. As a short runtime that allows the method to be used operationally and yet still offers a high quality of solution is crucial, a decomposition approach is implemented on the basis of a previous study and its suitability is validated by means of test runs.
CRIS-Team Scopus Importer:2023-03-07

Simulationsgestützte Auslegung manueller und automatisierter Prüfzellen in der Elektronikproduktion - Brossog, Matthias (Fachseminar „Simulation als Optimierungswerkzeug für die Produktion“, 2010)
Keywords: Montage; Simulation

Simulationsgestützte Produktionsplanung flexibler Fertigungssysteme - Selmaier, Andreas; Donhauser, Toni; Lechler, Tobias; Zeitler, Jochen Tobias; Franke, Jörg (wt Werkstattstechnik - Online, 2019)
While the behaviour of rigidly linked systems is relatively easy to model by means of material flow simulation, traditional simulation approaches are only suitable to a limited extent for flexible manufacturing systems due to the high data collection and parameterization effort. However, the use of real-time data can significantly improve the simulation of such systems. This paper presents an approach for simulation-based production planning of rapidly changing system
Keywords: simulation-based production planning; material flow simulation; realtime data

Simulationsgestütztes Vorgehensmodell zur Realisierung einer Matrixfertigung - Kirchberger, Manfred; Heeger, Madeleine; Altay, Alper; Liebrecht, Christoph; Overbeck, Leonard; Kandler, Magnus; Lanza, Gisela; Voigt, Christian; Franke, Jörg (Zeitschrift Kunststofftechnik, 2022)
Siemens AG in Karlsruhe is facing the current challenges of increasing product complexity with a higher number of variants, reduced batch sizes and shorter product life cycles. In order to restructure their manufacturing system towards a „matrix production in flow“, a process model for replanning and restructuring was designed to serve as a guideline. Supported by the digital twin and simulation studies, an optimized module configuration towards a highly flexible manufacturing with driverless transport vehicles is shown. Challenges such as complex production control can be supported by the digital twin.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Digital Twin; Holistic Production System; Matrix; Matrix Manufacturing System; Simulation

Simulation software design as a potential solution to the increasing complexity of industrial communication networks - Vukovic, Petar; Collischon, Matthias; Franke, Jörg (Procedia CIRP, 2020)
This paper presents results from a survey of industrial communication network administrators concerning their experience with these networks, complications in their operation as well as the utilization of simulation software. Our results show that most respondents consider these networks relatively complex and expect the complexity to increase in the future. Simulation software is seen as a potential counter to this complexity, but they are rarely used. Thus, we further provide a short introduction to simulation software for industrial communication networks.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Industrial communication; Industry 4.0; Network simulation; Survey

Simulation supported parameterization of reflow soldering processes Simulationsünterstutzte Parametrierung von Reflowlotprozessen - Kühl, Alexander; Alvarez, Christian; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2011)

Sintering of conductive inks on plastic substrates by use of microwave furnaces being suitable for largescale production processes - Hartmann, Lutz; Sabban, Jakob; Behrendt, Felix; Tatai, Tiberiu Mihai; Neermann, Simone; Franke, Jörg; Dreyer, Christian (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
This work is about the application of large-scale mi-crowave furnaces being suitable for the sintering of conductive structures deposited on standard plastic parts in industrial processes. The conductive structures are consisting of carbon or silver filled conductive inks. The feasibility of microwave sintering is proved by comparing the specific resistance of structures subjected to microwave sintering with conductive paths on reference samples sintered in a convection furnace. Furthermore, optical microscopy has been employed to inspect the surface morphology of conductive paths sintered by both microwave furnace and convection furnace. It turns out that appropriate microwave sintering depends on the specific way the magnetron power is controlled in the furnace and on the temporal evolution of magnetron power during the sintering process.
CRIS-Team Scopus Importer:2021-04-02
Keywords: conductive ink; conductivity; electromagnetic simulation; GFRP; microwave; sintering; specific resistance

Sintering of digitally printed silver nanoparticle inks on flexible and rigid substrates by NIR- And UVradiation - Roudenko, Jewgeni; Neermann, Simone; Schirmer, Julian; Reichenberger, Marcus; Franke, Jörg (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
In the research project AVerdi the influence of photonic sintering methods on the resulting electrical conductivity, sintering duration and adhesion of digitally printed silver nanoparticle inks was investigated and compared to convective sintering. Conductor paths with film thicknesses below 1 μ m were applied on flexible polymer substrates via inkjet printing. Aerosoljet printing was used to generate thicker lines up to 11 μ m on injection molded substrates. Photonic sintering was carried out with near infrared emitters or ultraviolet light emitting diodes. For inkjet printed structures on polyimide a conductivity up to 24 % relative to bulk silver was achieved after a sintering duration of 2 s and 5 s for the near infrared and the ultraviolet light source, respectively. Oven sintered samples showed an electrical conductivity of 14 % after 1 h at 200° C. On polyethylene terephthalate a conductivity around 7 % was achieved after irradiation with near infrared light for 1 s, whereas convectively sintered samples showed a conductivity around 4 %. All material combinations sintered by the different methods showed good adhesion. The overall results of long-term behavior after thermal-cycling, regarding electrical conductivity and adhesion, show that the photonically sintered structures achieve similar results compared to the reference. The photonically sintered structures generated with the aerosoljet on polyamide 6 achieved conductivity values up to 19 %, which were comparable to the furnace sintered reference samples. On liquid crystal polymer substrates conductivity values reached up to 35 % after sintering with ultraviolet light emitting diodes for 60 s. Oven sintered samples showed a conductivity around 25 % after 1 h at 150° C. The adhesion of the silver nanoparticle ink on liquid crystal polymer and polyamide 6 substrates is better than with the reference samples. The reliability tests show fewer failures with alternative sintered samples. In this study only the results for inkjet printed structures are presented.
CRIS-Team Scopus Importer:2021-03-26
Keywords: aerosoljet; electrical conductivity; inkjet; photonic sintering; printed electronics; silver nanoparticle ink

Six Sigma 4.0: Data Mining als unterstützende Technologie im Null-Fehler-Management - Schäfer, Franziska; Mayr, Andreas; Hess, Andreas; Zeiselmair, Christian; Otten, Heiner; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2019)

Skinning of Insulated Copper Wires within the Production Chain of Hairpin Windings for Electric Traction Drives - Gläßel, Tobias; Seefried, Johannes; Kühl, Alexander; Franke, Jörg (International Journal of Mechanical Engineering and Robotics Research, 2019)
Due to the influence of electric mobility drives used in the automotive powertrain are experiencing a boost in innovation. Caused by the accompanying demand for an increase in power density and the necessity to reduce costs in series production, the winding of electric machines and associated production processes are being improved. A promising novel type of winding is the bar-wound winding, which, in addition to numerous advantages, poses new demands on technologies for their production. In this case the winding is manufactured from a wide range of preformed elements made of enamelled copper wire, which must be connected to each other mechanically and electrically. For this purpose it is necessary to remove the insulation made of thermosetting material from the conducting elements in the joining area. Due to the large number of contacts that have to be prepared in this way, it gets essential to use productive and in particular process-safe skinning technologies. In this paper, the motivation for the application of bar-wound windings and the corresponding production chain is expounded. A method for the metrological quality control of residues in the skinned area is qualified and technologies for the realization of the skinning process are compared. In addition, experiments to create process knowledge for the laser-based removal of the insulation and the skinning by means of rotating brushes are presented.<br
Keywords: electric drives production; electric traction drives; hairpin winding; laser-based skinning; fluorescence based quality assurance

Skinning of insulated copper wires within the production chain of hairpin windings for electric traction drives - Gläßel, Tobias; Seefried, Johannes; Kühl, Alexander; Franke, Jörg (International Journal of Mechanical Engineering and Robotics Research, 2020)
Due to the influence of electric mobility drives used in the automotive powertrain are experiencing a boost in innovation. Caused by the accompanying demand for an increase in power density and the necessity to reduce costs in series production, the winding of electric machines and associated production processes are being improved. A promising novel type of winding with numerous advantages is the bar-wound winding, which introduces new demands on technologies for their production. This winding is manufactured from a wide range of preformed elements made of enameled copper wire, that must be connected to each other mechanically and electrically. For this purpose, it is necessary to remove the insulation of the conducting elements in the joining area. Due to the large number of contacts that have to be prepared in this way, it gets essential to use productive and in particular process-safe skinning technologies. In this paper, the motivation for the application of bar-wound windings and the corresponding production chain is expounded. A method for the metrological quality control of insulation residues in the skinned area is qualified and technologies for the realization of the skinning process are compared. In addition, experiments to create process knowledge for the laser-based removal of the insulation and the skinning by means of rotating brushes are presented.
CRIS-Team Scopus Importer:2020-03-20
Keywords: Electric traction drives; Fluorescence based quality assurance; Hairpin winding; Laser-based skinning

SmartEco - An Approach Using Electric Storage Heaters for Demand Side Management - Bürner, Johannes; Kleineidam, Gerhard; Braun, Thomas; Skibbe, Alexander; Franke, Jörg (Advanced Engineering Forum, 2016)

SmartEco: An Integrated Solution from Load Balancing between the Grid and Consumers to Local Energy Efficiency - Bürner, Johannes; Ditter, Alexander; Fey, Dietmar; Franke, Jörg (IEEE/ACM 8th International Conference on Utility and Cloud Computing (UCC), 2015)

SmartEco - Ein Ansatz zur Nutzung elektrischer Wärmespeicher zum Demand Side Management - Bürner, Johannes; Franke, Jörg (Tagungsband zum 1. E|Home-Symposium 2016, 2016)

Smart Energy and Grid: Novel Approaches for the Efficient Generation, Storage, and Usage of Energy in the Smart Home and the Smart Grid Linkup: Foundations, Principles, and Applications - Praß, Julian; Weber, Johannes; Staub, Sebastian; Bürner, Johannes; Böhm, Ralf; Braun, Thomas; Hein, Moritz; Michl, Markus; Beck, Michael; Franke, Jörg (Smart Cities: Foundations, Principles, and Applications, 2017)

Smarter Services 2016 - Bogner, Eva; Völklein, Thomas; Schrödel, Olaf; Franke, Jörg (SINTEC Informatik GmbH, 2016)

Smart Factory Meets Smart Grid: Cyber-Physical Compressed Air Systems Enable Demand Side Management in Industrial Environments - Böhm, Ralf; Bürner, Johannes; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production, 2015)
In electric energy systems based on renewable generation plants supply and demand often do not occur in the same period of time. Consequently demand side management is gaining importance whereby decentralized automation offers opportunities in industrial environments. Compressed air systems on industrial plants consist of air compressors, compressed air reservoirs and compressed air lines. With suitable dimensioning those industrial compressed-air systems can be used for demand side management purpose. As power consumption of industrial air compressors ranges between a few and several hundred kilowatts each, swarms of communicatively connected air compressors can contribute to the stabilization of power grids. To avoid costly production downtime it is to ensure, that a reliable, non-disruptive supply of compressed air can be maintained at all time. Industrial compressed air systems equipped with automation technology and artificial intelligence, which hereinafter are referred to as Cyber-Physical Compressed Air Systems (CPCAS), allow new business models for utilities, industrial enterprises, compressor manufacturers and service providers. In addition to basic operating parameters like current air pressure and status, those systems can process further information and create, for example, profiles on compressed air consumption over time. By enriching those profiles with data on pressure, volumes, system restrictions and current production requirements (plans), the CPCAS can identify the available potential for demand side management. Ipso facto predictive power on electricity consumption is increasing. By providing the information obtained to the power company or a service provider, savings in electricity costs may be achieved. Expenses within the industrial company may be lowered further as compliance with agreed load limits is being improved by automatic shutdown of air compressors upon reaching the load limit. Within this article the structure of the aforementioned Cyber-Physical Compressed Air Systems is presented in more detail, relations between the major actors are being shown and possible business models are being introduced.
Keywords: Cyber-Physical Systems; Demand Side Management; Energy Efficiency; Industrial Compressed-Air Systems

Smart Heating System for Old Buildings - An Approach to the Decentralized Use of Renewable Energies - Hein, Moritz; Stöber, Ralf; Fischerauer, Gerhard; Bürner, Johannes; Franke, Jörg; Feller, Martin; Maul, Joachim (Advanced Engineering Forum, 2016)

SMARTLOCATE – INDOOR LOCALIZATION WITH BLUETOOTH BEACONS AND SMARTPHONE SENSORS - Bauer, Jochen; Bakakeu Ngassam, Romuald Jupiter; Hopfengärtner, Michael; Bürner, Johannes; Braun, Thomas; Schäfer, Franziska; Wittmann, Maximilian; Fehrle, Adrian; Maußner, Benedikt; Lechler, Tobias; Meiners, Moritz; Konrad, Christoph; et al. (Smart Public Building 2018 Proceedings, 2018)

Smart Manufacturing Traceability for Automotive E/E Systems enabled by Event-Driven Microservice Architecture - Kuhn, Marlene; Franke, Jörg (2020 IEEE 11th International Conference on Mechanical and Intelligent Manufacturing Technologies, 2020)
Keywords: Traceability; Microservice; E/E system; Autonomous driving; Event-driven architecture

Smartphone-Based Hyperspectral Imaging - Low-Cost Application for Telemedicine - Vogt, Johanna; Martin, Sina; Franke, Jörg (dHealth 2023, 2023)
In this paper we outline a cost-effective design for the improvement of telemedicine applications through a two components concept. A normal smartphone is equipped with a small device containing different filter options, which provide particular spectral information for the identification of skin lesions. By merging the measured spectra, a higher data density and more information can be obtained using an ANN to improve an early diagnosis of skin lesions through telemedicine applications in remote areas.
CRIS-Team Scopus Importer:2023-06-02
Keywords: artificial intelligence; hyper spectral imaging; smartphone-based application; telemedicine

Smart use case picking with DUCAR: A hands-on approach for a successful integration of machine learning in production processes - Schäfer, Franziska; Mayr, Andreas; Schwulera, Erik; Franke, Jörg (Procedia Manufacturing, 2020)
The increasing data availability in production processes combined with open source software tools in the field of machine learning (ML) lead to a new level of process improvement possibilities. For many companies, the challenge is now to identify potential use cases with considerable business impact by integrating ML techniques in production processes. Especially hands-on approaches, which provide a structured guideline through the process with concrete tools, are missing. Therefore, this paper presents the smart use case picking approach DUCAR, which consists of five phases. The first phase is the definition of the ML use case domain followed by the understanding of potential processes and process steps in the second phase. In the third phase, use case ideas are collected based on the gained knowledge. After the analysis and selection of the most promising use cases in the fourth phase, the final fifth phase focuses the realization of these use cases to successfully integrate ML in production processes. To validate the DUCAR approach, the field of electronics production is used as an example.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Machine learning; Manufacturing; Process improvement; Production; Use case

Soft Jamming Gripper with the External Prominence of Membrane for Human-Robot Cooperation - Shahsevani, Rasool; Reitelshöfer, Sebastian; Alimardani, Reza; Franke, Jörg (2019 IEEE 7TH INTERNATIONAL CONFERENCE ON CONTROL, MECHATRONICS AND AUTOMATION (ICCMA 2019), 2019)
CRIS-Team WoS Importer:2020-07-17

Soft Robotics mit DEA: Künstliche Muskeln für Roboterkollegen - Yoo, In Seong; Landgraf, Maximilian; Reitelshöfer, Sebastian; Franke, Jörg (Handling, 2015)

Software-in-the-loop testbed for multi-agent-systems in a discrete event simulation - Scholz, Michael; Oberschachtsiek, Stefan; Donhauser, Toni; Franke, Jörg (2017 IEEE International Symposium, 2017)

Solderability of Injection Moldable Thermoset Resins for Use in 3D Mechatronic Integrated Devices - Häußler, Felix; Petillon, Simon; Dornheim, Johannes; Weser, Sascha; Eberhardt, Wolfgang; Zimmermann, Andre; Franke, Jörg (2020 43RD INTERNATIONAL SPRING SEMINAR ON ELECTRONICS TECHNOLOGY (ISSE), 2020)
Increasing demands regarding reliability of mechatronic systems and the aim for miniaturization require new materials and processes for the 3D mechatronic interconnect devices (3DMID) technology to fulfill those demands. For the first time, this paper demonstrates the solderability of a new material class for 3D-MID applications, down to the SMD component size 01005. Instead of standard and state-of-the-art thermoplastic materials such as polyamide or high-performance thermoplastic materials commercial injection moldable thermoset resins were used. They were selectively metallized by laser structuring and electroless plating. Different laser parameters for structuring of two different substrate materials were investigated. SMD resistor components with the size 0805, 0402, 0201 and 01005 were used to evaluate material solderability on stencil printed solder pads. Specimen were analyzed using optical analysis, metallographic examination and shear tests. The results show that component size and laser energy have the most significant effect on shear strength and defects. Eligibility for common soldering processes in electronics packaging was proven. Additionally, soldering results between convection soldering and vapor phase soldering were compared, showing higher shear forces for samples soldered in the convection oven. Based on the results the tested injection moldable thermoset resins are suited as circuit carrier material in electronic packagin
CRIS-Team WoS Importer:2021-02-26

Spontaneous shrinkage drives macromolecule encapsulation into layer-by-layer assembled biopolymer microgels - Campbell, Jack; Taghavi, Aaron; Preis, Alexander; Martin, Sina; Skirtach, Andre G.; Franke, Jörg; Volodkin, Dmitry; Vikulina, Anna (Journal of Colloid and Interface Science, 2023)
Hypothesis: Recently, the anomalous shrinkage of surface-supported hyaluronate/poly-L-lysine (HA/PLL) microgels (µ-gels), which exceeds that reported for any other multilayer-based systems, has been reported [1]. The current study investigates the capability of these unique µ-gels for the encapsulation and retention of macromolecules, and proposes the shrinkage-driven assembly of biopolymer-based µ-gels as a novel tool for one-step surface biofunctionalization. Experiments: A set of dextrans (DEX) and their charged derivatives - carboxymethyl (CM)-DEX and diethylaminoethyl (DEAE)-DEX - has been utilized to evaluate the effects of macromolecular mass and net charge on µ-gel shrinkage and macromolecule entrapment. µ-gels formation on the surface of silicone catheters exemplifies their potential to tailor biointerfaces. Findings: Shrinkage-driven µ-gel formation strongly depends on the net charge and mass content of encapsulated macromolecules. Inclusion of neutral DEX decreases the degree of shrinkage several times, whilst charged DEXs adopt to the backbone of oppositely charged polyelectrolytes, resulting in shrinkage comparable to that of non-loaded µ-gels. Retention of CM-DEX in µ-gels is significantly higher compared to DEAE-DEX. These insights into the mechanisms of macromolecular entrapment into biopolymer-based µ-gels promotes fundamental understanding of molecular dynamics within the multilayer assemblies. Organization of biodegradable µ-gels at biomaterial surfaces opens avenues for their further exploitation in a diverse array of bioapplications.
CRIS-Team Scopus Importer:2023-01-06
Keywords: Encapsulation; Hard templating; Multilayer; Surface functionalization; Vaterite

Standardizing Process Optimization for Production Processes in the Control Cabinet Industry: A Multiple Case Study - Stoidner, Micha; Bründl, Patrick; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (2023 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM), 2023)
This paper presents a multiple-case study that aims to standardize process improvement in the control cabinet industry and identify areas requiring significant enhancements. The study provides a comprehensive understanding of observed processes, facilitating efficient process design and waste identification. A standardized process survey is developed and applied to a third control cabinet manufacturing company for validation. The findings reveal limited coverage of the control cabinet industry in existing studies. Eleven challenges faced by control cabinet manufacturing companies are identified, including a shortage of skilled workers and limited space. The analysis highlights low evaluations in all seven fields of action. Recommendations include implementing material flow to improve efficiency and identify bottlenecks. The study introduces a systematic analysis framework for evaluating production sites in the control cabinet industry, contributing to operations research and practical applications. It offers a comprehensive framework for analyzing and optimizing control cabinet production processes. Future research should focus on assessing applicability to small and medium-sized enterprises in other industries with similar inefficiencies.<br
Keywords: Industries; Surveys; Systematics; Operations research; Process control; Production; Companies; Control Cabinet Manufacturing; Process optimization; Process recording; Multiple Case Study

Static Versus Dynamic Provision of Worker Information in Manual Assembly: A Comparative Study Using Eye Tracking to Investigate the Impact on Productivity and Added Value Based on Industrial Case Examples - Lusic, Mario; Fischer, Christian; Braz, Konrad Schmutzer; Alam, Marina; Hornfeck, Ruediger; Franke, Jörg (Procedia CIRP, 2016)
Manual product assembly is usually done by providing worker information accordingly to the present assembly task. Traditionally, paper-based systems are used for this purpose, but nowadays, IT-based worker information is gaining ground. Those systems in particular allow the transmission of dynamic information and, thus, enable a realistic and timely representation of assembly sequences. Previous comparative studies on the effective difference between static and dynamic provision of worker information have two gaps. On the one hand, the majority investigated less manual assembly tasks close to real industrial cases. The experiments take place rather on abstracted assembly models under research laboratory conditions. On the other hand, there is a lack of studies on the efficiency of the interaction between the information providing medium, the available assembly objects and the actual worker's behaviour. This is regarded in a way simultaneous to the assembly process and from a real view of the worker. To be able to draw conclusions about the efficiency of this interaction, a real view registry, which is provided by the yet sparingly applied eye tracking technology, is feasible. The experiments described in this article draw on both aspects to realise a lifelike as possible comparison between static and dynamic provision of worker information: Based on industrial case examples, and thus close to a real working environment, the worker's eye movement is documented specifically for the assembly tasks and afterwards holistically analysed in concern of the impact on productivity and value adding.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Eye tracking; Information; Productivity; Value adding

Strategic energy management in industry 4.0 environment - Javied, Tallal; Bakakeu, Jupiter; Gessinger, Dennis; Franke, Jörg (12th Annual IEEE International Systems Conference, SysCon 2018 - Proceedings, 2018)
One of the latest innovations in the industrial environment was the emergence of Industry 4.0. Along with numerous challenges, there are many chances for companies in it. Besides automation, energy efficiency and energy flexibility is becoming increasing important. Because of the planned phasing-out of nuclear power and high prices for energy, it is important for companies to reduce their energy consumption in order to reduce cost and stay compatible in market place. Therefore strategic energy management plays an important role in overcoming these obstacles. Implementation of energy management is often based on standards and norms with the DIN EN ISO 50001 being the most important. Energy monitoring is a key factor for the successful execution of energy management. For energy monitoring of Industry 4.0 production plants, a cloud based energy monitoring and management system was developed. This solution allows users to monitor their production in real time enabling them a possibility of condition monitoring, energy flexible planning of production based on historic data and energy management along with load management. The detailed concept of the cloud based totally integrated energy management system, beginning with data acquisition to data analysis and visualization is presented in this paper.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy management; Energy monitoring; Industry 4.0

Strategies and Methods for the Energy Efficient Production of Electric Drives - Kreitlein, Sven; Hofmann, Benjamin; Meyer, Alexander Wilhelm; Spreng, Simon; Kühl, Alexander; Franke, Jörg (Procedia CIRP, 2016)
This paper presents methods and experiments for the assessment and evaluation of energy efficiency strategies for manufacturing processes in the field of electric drives production. First, the system for the Least Energy Demand Method will be explained. The basic idea of this calculation is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the measured energy consumption. Using these values as well as further derived indicators for energy efficiency, the main energy consumers within the field of electric drives production are identified. Subsequently, these processes are analysed and optimized to achieve major energy saving instructions. From an energy point of view during the stator production chain, especially the impregnation process and the joining process have to be optimized as, in the here presented measurements, the impregnation process amounts to more than 80 % of the cumulated energy demands. Moreover, the process of joining insulated copper wires of the stator windings to corresponding cables shoes is optimized, as it shows strong energy saving potentials. Additionally, the power consumption values within the state of the art joining process are varying strongly thus leading to higher load peaks within the production line, which have to be reduced. Regarding energy efficiency within the manufacturing of permanent magnet synchronous rotors, the process of magnet assembly also has to be evaluated. It can be subdivided into magnet manufacturing, logistics, magnetization and assembly. A major part of the energy used in this process is accounted for by means of transportation, especially when considering that magnetized magnets need larger packaging volumes and weights due to the ferromagnetic shielding and spacers to support handling of the magnet bodies. Thus, the energy efficiency can be increased considerably by shifting the magnetization step directly to right before the assembly step. In addition, energy can be saved by optimizing the magnetization process according to the magnetization strategy and the interaction of all process parameters, such as capacity of the magnetizer, inductivity and size of the magnetizing coil, magnet size, material and coating.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electric drives production; Energy efficiency; Least Energy Demand Method; Manufacturing strategy

Streamlining the development of data-driven industrial applications by automated machine learning - Kißkalt, Dominik; Mayr, Andreas; Lutz, Benjamin; Rögele, Annelie; Franke, Jörg (Procedia CIRP, 2020)
Machine learning has often proven superior to traditional white-box modeling in industrial application scenarios. Yet the determinism in finding a solution close to the theoretical optimum is low due to human factors in the development process. Automated machine learning (AutoML), on the other hand, allows a complete automation of the machine learning pipeline from feature extraction and preprocessing to model selection and hyperparameter optimization. Using a popular open dataset, this paper exemplifies how AutoML can streamline the development of data-driven industrial applications. As a benchmark, results from existing approaches on the same dataset are used.
CRIS-Team Scopus Importer:2020-10-23
Keywords: Automated machine learning; AutoML; Machine learning; Machining; Tool monitoring

Strength Calculation and Design Optimization of a Test Rig for Slide Ring Seals in the Scope of Rotary Manifolds - Müller, Julian; Michos, Gordana; Koch, Lukas; Hubert, Markus; Franke, Jörg (AMM (Applied Mechanics and Materials), 2017)
An examination of machining centers with high degree of automation showed that rotatory manifolds are critical components regarding functional reliability and efficiency. In order to get a better understanding of the interrelationships and involved mechanisms of the sealing system inside the rotatory manifolds, a corresponding rotatory seal test rig was developed. This study presents the necessary development process. More importantly, both of the analytical and simulative strength verification of the pressure chamber design is elucidated.

Stretchable, multi-modal sensors for vital data monitoring and healthcare applications - Martin, Sina; Reitelshöfer, Sebastian; Franke, Jörg (2021)
Keywords: flexible electronics; flexible sensors; silicones; soft sensors; healthcare; vital data monitoring; printed electronics

StroMiS - Studie zur technisch-wirtschaftlichen Analyse der Stromerzeugung aus Mikrokraftwerken in Serienfertigung - Scholz, Michael; Kühl, Alexander; Höft, Annika; Landgraf, Maximilian; Schneider, Michael; Böhm, Ralf; Badel, Gregor; Lothes, Gerald; Angerer, Kerstin; Hohmann, Andrea; Simon, Peter; Konwitschny, Fabian; et al. (2019)

Structural mechanic finite element analysis of the bend and torsion behavior of high-voltage cables - Bönig, Jochen; Spahr, Michael; Fischer, Christian; Franke, Jörg (3rd International Electric Drives Production Conference, 2013)
The use of electric power systems in automobiles represents a massive change in the production line of car manufacturers. To guarantee an efficient and at the same time damage free installation of the current carrying high-voltage cables, virtual validation of assembly operations makes an important contribution. On the market available simulation tools like IC:IDO Flexible II, IPS Cable Simulation and TEA Pipe compute the rigidity of the cable system by using substituted material properties. The high-voltage cable producers don't provide these substituted parameters. Measuring the properties during a physical experiment is inefficient because of the high time exposure and costs. The complex structure of the high-voltage cables and the high number of variants lead to the advantage of simulation opposite experiment. So the need for research is a finite element model to generate the necessary substituted material properties in a time and cost efficient way. To achieve this goal, bend and torsion tests of detailed cable models are simulated and matched with experimental results for validation. Under the premise of the plastic material behavior of the wire and the interface friction between the individual cable components, different mesh strategies are evaluated. The performance of beam against solid element meshed wires is crucial and the element size influence to the result quality is researched. For a robust convergence the complex contact problem is mapped by the Augmented-LaGrange algorithm and the fitted contact stiffness between the individual cable components. The results are the influence of the plasticity and the interface friction to the change of the stiffness properties depending on the cable load.
Keywords: E|DRIVE; E|SYS; Simulation

Structural mechanics process simulation of linear coil winding - Bönig, Jochen; Bickel, Benjamin; Ebenhöch, Matthias; Spahr, Michael; Fischer, Christian; Franke, Jörg (Trans Tech Publications Ltd, 2014)
Slowly but steadily, more and more electrical vehicles push onto the consumer market. To produce electrical engines cost efficiently, in first-class quality and in sufficient quantity, it is indispensable to understand the process of winding. The prediction of the wire behaviour is one of the key challenges of coil winding. It is sophisticated and sometimes impossible to measure relevant process parameters (like the wire pull force after wire guide, the wire stress after deformation) in experiments in order to be able to investigate the process in detail. Therefore, a detailed model is built to simulate the wire behaviour during linear winding process. The finite element based simulation tool ANSYS Workbench® serves as the static structural component tool. ANSYS provides comprehensive possibilities in structural mechanics and it is possible to simulate thermal and electrical physics for future work (Co-simulation within one 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 neglected. Within static structural analysis, the given boundary conditions are applied to the model. The material properties of wires under scrutiny are validated by a tensile test and by the values of datasheets. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behaviour. Furthermore, some adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers good process parameters and, thus, expertise in winding technology. However, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of the winding process, where varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in this field. The generated model enables users not only to influence the process parameters but also to modify the geometry of the winding body. To make the simulation scientifically sound, it is validated by experiments.
Keywords: Coil winding; Simulation; Structural analysis

Studies and Analyses of Moisture Conditioned SMT-Components - Haas, Lukas; Döpper, Frank; Schmidt, Konstantin; Franke, Jörg; Reinhardt, Andreas (2021 23rd European Microelectronics and Packaging Conference & Exhibition (EMPC), 2021)
One of the most challenging aspects of processing electronic parts is the abundance of influencing factors. These have a significant impact on the quality of the finished product. Particularly the affinity to embed moisture in the plastic matrix can lead to severe damage mechanisms. With a moisture gain of up to 0.5 percent by weight [1] delamination and the so-called “popcorn effect” may occur during reflow soldering [2]. This is due to the explosive vaporization and volume gain the embedded water experiences during the heating process. To prevent these failures the floor time has been established. It specifies the maximum amount of time a Surface Mount Device (SMD) can be exposed to certain conditions (floor life) before failures start to occur. After the floor life ends, time-consuming and costly preconditioning in a warm and dry atmosphere is necessary to restart the floor time. The Moisture Sensitivity Level (MSL) in combination with the JEDEC standard defines the exact conditions and times for preconditioning.The proposed article focuses on modeling cause-effect-relations between influence and target values to create a more efficient way to determine when preconditioning is necessary. A literature review of research papers and industry standards is used to determine the quality defining influence parameters. Transferring these insights into two simulation models, one based on the Fickian diffusion mechanism, the other on the two-stage Fickian diffusion, leads to a promising approach for concluding reversible and irreversible moisture diffusion into the SMD components.An experimental setup is determined using the derived dependence model. The experiments consist of defined loading and drying cycles of different samples of MSL 3 and 4 to quantify the moisture de- and absorbed by the part under defined conditions. Subsequently, several differently moisture-loaded parts are reflow soldered to recreate a variety of failure mechanisms. Which, in turn, are used to verify the critical moisture mass absorbed by the SMD-components
Keywords: Phase change materials; Atmospheric modeling; Moisture; Production; Packaging; Manufacturing; Integrated circuit modeling; smt; diffusion; floor life; two-stage diffusion; electronics production

Study Based Analysis on the Current Digitalization Degree in the Manufacturing Industry in Germany - Bogner, Eva; Völklein, Thomas; Schrödel, Olaf; Franke, Jörg (Proceedings of the 49th CIRP Conference on Manufacturing Systems 2016, 2016)
The fourth industrial revolution and the digital transformation are already major factors in the manufacturing industry and their importance is ever growing. However, the degree of their practical implementation has to be scrutinized. To define a status quo, it is important to analyze the situation and to identify deficits, starting points and unexploited potentials.Still, a detailed understanding of the fourth industrial revolution and the digital transformation is lacking especially in small and medium sized manufacturing companies. In addition, the fourth industrial revolution is associated by most companies only with logistics as well as production and manufacturing areas. The opportunities to integrate additional functional areas of the production process and the vertical value chain into the concept of the fourth industrial revolution are hardly considered. Starting from the point of view that the fourth industrial revolution is defined as a systematic increase in the flexibility of products and processes through automation, extensive networking and decentralized control mechanisms, as well as a data acquisition and integration through information and communication technologies, a study concept is developed. For this purpose, it is not enough to ask only for the present prevalence of technologies of the fourth industrial revolution. It is necessary to analyze the processes within manufacturing companies.A survey concept is developed that initially breaks down the vertical value chain as well as the production process into specific sub-processes. These sub-processes are analyzed regarding their degree of automation and digitalization and networking among themselves. The results of this survey presents concisely the call for action, the state of implementation and realized solutions of the fourth industrial revolution in Germany. Furthermore, impulses and best practices for innovative products and business models can be given.
Keywords: Digital transformation; Digitalization degree; Fourth industrial revolution; Study

Substituting bond wires by additively manufactured interconnections - Lomakin, Konstantin; Sippel, Mark; Gold, Gerald; Ringel, Johannes; Weiß, David; Helmreich, Klaus; Ankenbrand, Markus; Franke, Jörg (German Microwave Conference, 2018)
This work shows a comparison of microstrip to integrated circuits junction between conventional bond wires and additively manufactured signal interconnect. Therefore, an approach for reducing signal reflection is proposed and implemented on a test board fabricated on typical radio frequency substrate material. Measurements up to 24 GHz reveal improved performance as compared to conventional technology in terms of reflection suppression and transmission losse

Substrate pretreatments: an investigation of the effects on aerosol jet printed structures - Neermann, Simone; Scheetz, Matthias; Franke, Jörg; Roudenko, Jewgeni; Schirmer, Julian; Reichenberger, Marcus (WGP-Jahreskongress, 2018)

Suitability of a 2 kw 515 nm Continous Wave Laser for Deep Penetration Welding of Copper - Ockel, Manuela; Hensel, Alexander; Franke, Jörg (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
With advancing electromobility the demands regarding electrically conductive copper connections are increasing. In order to withstand the critical conditions in an electric traction motor the connections have to be stable and of high quality. Welding is a possible method to produce material bonded joints that, while fulfilling the requirements regarding electrical conductivity and mechanical stability, also allow for an increased integration density and reduced construction space by substituting screw connections. Especially laser welding offers a flexible, fully automatable approach while only needing single-sided optical access to the welding spot. While being an established industrial process, the joining of copper via laser-welding is still classified as difficult. The high thermal conductivity and low absorptivity of copper for infrared wavelength is challenging for a stable welding processes and sensitive to different material properties like material thickness, oxidation and roughness. Green wavelengths have significantly higher absorption rates at room temperature and are less sensitive to absorption-dependent material properties. The advantages are clearly visible in heat conduction welding applications. If these advantages are also applicable to a deep penetration welding process is investigated in this paper. The results are compared with weld seams produced by state-of-the-art industrial infrared lasers.
CRIS-Team Scopus Importer:2023-03-07
Keywords: absorption; copper welding; deep penetration laser welding; green laser; infrared laser

Superordinate Control Structure for Hybrid Compensation Systems - Böhm, Ralf; Paulsburg, Martin; Franke, Jörg (Advanced Engineering Forum Volume 19, 2016)
Medium voltage grids are subject to a change in load situation due to the installation of decentralized generation plants. Predominantly load symmetry, active and reactive power as well as the required capacity of earth fault compensation is affected. Inverter-based plants as well as consumers using switching power supplies or phase control cause distortions of frequency. Simultaneously electrical energy storage is gaining importance within rural distribution networks to compensate fluctuating generation plants. A hybrid compensation system includes a transformer, a multi-phase inverter, diverse storage systems and a communication-capable control unit, which may be connected to the control center of the distribution system operator (DSO). It is object to current research activities to design and evaluate the functions of the superordinate control unit, which has to parametrize individual components, coordinate the energy flows between them and to embed several measuring instruments. Within the present work, basic considerations for design of system control are outlined.
Keywords: Ancillary Services; Power System Harmonics; Digital Signal Processing

Sustainability Aspects of Current Market Developments, Different Product Types and Innovative Manufacturing Processes of Electric Motors - Mayr, Andreas; Weigelt, Michael; Masuch, Michael; Adrion, Martin; Bauer, Aljoscha; Wirsinger, Katrin; Franke, Jörg (Applied Mechanics and Materials, Vol. 882, 2018)

Sustainable Intralogistics due to Uniform Software and Modular Transport Entities - Scholz, Michael; Zwingel, Maximilian; Schuderer, Peter; Franke, Jörg (Procedia CIRP Volume 80, 2019)
The current trend in internal value stream structures shows a clear development towards a combination of the specific advantages of the operation-oriented and the process-oriented production systems. All scientific approaches have in common that flexible intralogistics production networks require an autonomous and intelligent transportation systems that is not designed for a specific task, but can take on different transport roles due to their versatility. However, a comprehensive analysis of current designs and research projects in the field of AGVs and intralogistics transport robots show that there is neither the necessary interoperability of different systems nor a system architecture that addresses a flexible material flow independent of the physical design of the transportation system. AGVs mainly have a central control system, which manages the generation of transport orders and their disposition on the vehicles. In addition, the routes are specified centrally for the vehicles, even if they have free navigation. The individual transport unit is therefore only an executing machine that processes the assigned transport orders without any influence on order dispatching or route planning. Therefore, these AGV approaches do not have the flexibility and autonomy required for an intralogistics production network. The research project addresses the necessary interoperability of logistics systems and the abandonment of proprietary standalone solutions. For this purpose, methods for digitizing the workspace, route planning and path execution using a service-oriented architecture (SOA) were developed. A central component of this architecture is the approach described in the paper to enable decentralized path planning on the vehicles. Therefore, the path planning must be applicable to different target platforms without implementation effort and the vehicle software must be designed independently of the application. This approach allows intralogistics systems to be flexible and adaptable, resulting in a more sustained use of these system
Keywords: Sustainable Production Systems; Autonomous Transport Systems; Uniform Software; Modular Intralogistics

Synthesizing CRISP-DM and Quality Management: A Data Mining Approach for Production Processes - Schäfer, Franziska; Zeiselmair, Christian; Becker, Jonas; Otten, Heinrich (2018 IEEE International Conference on Technology Management, Operations and Decisions (ICTMOD), 2018)

System architecture and conception of a standardized robot configurator based on microservices - Schäffer, Eike; Pownuk, Tobias; Walberer, Joonas; Fischer, Andreas; Schulz, Jan-Peter; Kleinschnitz, Marco; Bartelt, Matthias; Kuhlenkötter, Bernd; Franke, Jörg (Tagungsband des 3. Kongresses Montage Handhabung Industrieroboter, 2018)
The design and integration of robotic-based automation solutions is a common problem for robotic component providers and especially for their consumers. In this work, a standardized robot configurator is introduced, based on a modular system architecture and best-practice solutions. Starting with a minimum viable prototype providing an intuitive web-based configurator, customized robot applications can easily be planned, visualized, simulated and finally realized. The presented robotic configurator is based on microservice architecture, which is a modern, scalable and complexity-reducing solution for the overall system. This paper demonstrates how an exemplary configuration process could be handled to get an impression about the prospective use of pre-configured robotic solutions. <br
Keywords: Configurators; robot configuration; microservice architecture; minimum viable prototype

Systematic Consideration of Value Chains with Respect to the Timing of Individualization - Bogner, Eva; Löwen, Ulrich; Franke, Jörg (Proceedings of the 27th CIRP Design Conference, 2017)
Increasing variety of customer requirements and product variants lead to extended complexity in development and manufacturing. Especially the management of development and manufacturing with respect to customer specific and individualized products becomes more and more challenging. However, the issue of customer specific and individualized products is often reduced to the strategy of mass customization. The complexity of this topic requires a holistic approach in order to structure and analyze individualization along the entire value chain. Only if such an understanding is created, the issue of individualization can be addressed adequately to meet the increasing flexibility requirements and growing complexity. For this reason, a systematic classification has to be developed to understand the characteristics of and the options for individualization as well as to enable its applicability. Nevertheless, existing approaches are often incomplete and superficial. Furthermore, many terms in the context of individualization are neither defined nor used consistently. Consequently, the aim of this work is to create an overarching systematization that closes the gaps in existing approaches and provides unambiguous terms. Furthermore, this approach should holistically visualize individualization and illustrate its impact to the core value chains in manufacturing industries.
Keywords: Individualization; Value Chain; Customer Decoupling Point

Systematic energy management: A foundation for sustainable production - Javied, Tallal; Esfandyari, Alireza; Franke, Jörg (2016 IEEE Conference on Technologies for Sustainability, SusTech 2016, 2017)
In the past few years energy management became increasing important. Not only the trend toward clean energy sources triggered a process of rethinking in the minds of society but also pushed the politics to create incentives for companies in order to make them reduce their carbon footprint. Efficient use of resources has become a fundamental part of present-day economic, social and political decision making. Energy efficient production is no longer considered just under ecological aspect. It is considered as an important part of business strategy. Through high energy taxes, enormous energy costs and continuously increasing energy prices manufacturing companies are under permanent stress. However, there is for companies in the field of energy management enormous potential to financially improve and save costs consequently. Standards have provided a guide line for the companies to move towards green production. However lack of know-how and appropriate software tools and absence of concepts and methods for green production hinders company's especially small and medium size enterprises to take the step towards green production. Systematic and strategic energy management is the key to transform a company from lean to green production. Because of the complexity of the tasks related to environment and energy management, the Institute for Factory Automation and Production Systems (FAPS) developed methods and concepts to implement a strategic energy management. Furthermore, a software is developed that enables companies to follow the ISO 50001 guidelines and implement energy management methods necessary for a green production. This paper provides a brief road map showing the path to an energy efficient production environment. Starting from the list of the main energy consuming applications in German industries, which were identified through a study carried out in 2015. Brief description of the energy management methods and concepts and illustration of the role of strategic energy management in transforming companies from lean to green production and finally a brief illustration of the software for the implementation of energy management especially in manufacturing companies.
CRIS-Team Scopus Importer:2023-03-07
Keywords: energy efficiency; energy management; sustainable production

Systematic Qualification of Layer Thickness, Roundness and Defects of Screen-printed Magnetic Sheets - Schmidt, Alexander; Wieprecht, Nico; Cosack, Alexander; Janisch, Lucas; Franke, Jörg; Kühl, Alexander (2023 13th International Electric Drives Production Conference (EDPC), 2023)
Screen printing offers the potential to produce near net shape and ultra-thin magnetic sheets for electrical machines. This is accompanied by significant potential for increasing performance. In this publication, the influence of various parameters on the geometric green part properties of screen-printed magnetic sheets is systematically analyzed by statistical design of experiment. The factors iron paste, design, substrate carrier and squeegee speed on the quality characteristics layer thickness, roundness, defects, and cycle time are considered. The aim of the investigation is to determine the main influencing factors and interactions on the target variables and the subsequent derivation of suitable parameter combinations by target variable optimization.<br
Keywords: Printing; Electric potential; Systematics; Shape; Production; Magnetic analysis; Substrates; Additive Manufacturing; Electric Motor; Magnetic Sheets; New Materials; Screen Printing

Systematische Methodenauswahl bei der Digitalisierung - Selmaier, Andreas; Martens, Benedikt; Sjarov, Martin; Kuhn, Marlene; Herbert, Meike; Franke, Jörg (Werkstattstechnik, 2020)
Digitalisierungsprojekte sind Softwareprojekte. Sequentielle Planungsmethoden, wie sie im konventionellen Projektmanagement überwiegend Anwendung finden, eignen sich jedoch nur bedingt für diesen Projekttyp, da die anwendungsspezifischen Anforderungen sowie die Abhängigkeiten der Anlagen und IT-Systeme untereinander zu einem erheblichen Anstieg der Gesamtkomplexität führen. In diesem Beitrag wird daher ein Ansatz zur systematischen Auswahl geeigneter Projektmanagementmethoden für Digitalisierungsprojekte vorgestellt, welcher die traditionelle Projektplanung im Produktionsumfeld um iterative Vorgehensweisen aus der Softwareentwicklung ergänz
Keywords: Produktionsmanagement; Digitale Fabrik; Industrie 4.0

Systematische Risikobewertung für eine additiv gefertigte, kosteneffiziente Handprothese - Yoo, In Seong; Peipp, Matthias; Franke, Jörg (2. Transdisziplinäre Konferenz – Technische Unterstützungssysteme, die die Menschen wirklich wollen, 2016)
Keywords: Additive Manufacturing; B|Mech; Prothetik

Systematisierung von Wertschöpfungsketten im Hinblick auf die Produktion kundenindividueller Produkte - Bogner, Eva; Löwen, Ulrich; Franke, Jörg (Konferenzband zur 1. interdiszplinären Konferenz der Zukunft der Wertschöpfung, 2016)
Im Kontext der vierten industriellen Revolution wird maßgeblich von einer zunehmenden Flexibilisierung und Individualisierung in der produzierenden Industrie gesprochen. Eine Vision unter dem Schlagwort „Mass Customization“ sind Wertschöpfungsketten zur Fertigung kundenindividueller Produkte in Losgröße 1 mit der Effizienz einer vergleichbaren Massenproduktion. Vor dem Hintergrund der starken Heterogenität innerhalb der produzierenden Industrie ist es jedoch fraglich, inwiefern es tatsächlich zu einer Konsolidierung der unterschiedlichsten bisher verfolgten Produktionsstrategien auf eine einheitliche Strategie der Mass Customization kommen wird. Vielmehr gilt es herauszuarbeiten, durch welche Komplexität die Individualisierung innerhalb der produzierenden Industrie geprägt ist. Dabei zeigt sich, dass es nicht genügt, die Individualisierung nur aus einer Perspektive zu betrachten. Um Individualisierung in Produktionsstrategien zu beschreiben, muss eine Definition über mehrere Dimensionen der Wertschöpfung hinweg geschaffen werden. Die Entwicklung einer mehrdimensionalen Systematik dient der Strukturierung und Beschreibung der unterschiedlichen Ausprägungen von Wertschöpfungsketten für die Produktion kundenindividueller Produkte.
Keywords: Individualisierung; Produktionsstrategie; Produzierende Industrie; Mass Customization; Industrie 4.0

System Concept of a Robust and Reproducible Plasma-Based Coating Process for the Manufacturing of Power Electronic Applications - Hensel, Alexander; Müller, Martin; Franke, Jörg; Kohlmann-von Platen, Klaus (7. WGP-Jahreskongress Aachen, 5.-6. Oktober 2017, 2017)
The increasing integration of power electronics in various applications like energy distribution, hybrid and electric mobility or consumer products requires a steady improvement of interconnection technologies in order to increase reliability, efficiency and life expectancy of power modules. Currently the standard technology used for top level interconnection is the aluminum wire bonding process. Thereby wires are friction welded both on dies and substrates by the use of ultrasonic in order to create a local cohesively connection. Due to the limitation of aluminum regarding the mechanical, thermal, and electric characteristics, the use of alternative materials like copper is preferred. However, due to the higher hardness of copper, copper wire bonding on the previous aluminum metallization of the components is not possible, so that an additional copper metallization is necessary to be applied. Common processes for the metallization of semiconductors like PVD or galvanic metallization are either expensive or require extensive follow up processes like back etching. In order to provide another suitable method a plasma based coating unit for copper particles has been installed.
Keywords: Plasma; Thermische Beschichtungsverfahren

Systems Engineering als Basis für konstruktionsbegleitende Zusammenarbeit - Russwurm, Eva; Faltus, Florian; Franke, Jörg (Tagungsband Virtueller ASIM Workshop 2021 Simulation Technischer Systeme. Grundlagen und Methoden in Modellbildung und Simulation & Edukation und Simulation, 2021)
Der Ansatz des Systems Engineering (SE) unterliegt einem stetigen Wandel und wird bereits in vielen Unternehmen im Rahmen der Produktentwicklung eingesetzt. Dieser Ansatz, der in Zusammenarbeit, Effizienz und Produktqualität, sowie Kosten viele Vorteile bietet, kann den Herausforderungen der Industrie 4.0 begegnen. Zur Umsetzung des SE werden verschiedene Werkzeuge benötigt. Dazu gehören neben einem PLM-System zur entwicklungsbegleitenden Zusammenarbeit auch verschiedene Simulationsumgebungen, die zu einer Co-Simulation zusammengeführt werden. Eine Möglichkeit, hierfür Kommunikation zu ermöglichen, bietet hier die Verwendung des Kommunikationsstandards OPC UA. Die Anwendung des SE-Ansatzes soll anhand von zwei Anwendungsbeispielen dargestellt werden, nämlich anhand einer ganzheitlichen Simulation einer Produktionsanlage mit Energiemanagement und in einer Lehrveranstaltung. <br
Keywords: SystemsEngineering; Produktentwicklung

Tailored heat treated accumulative roll bonded aluminum blanks: Microstructure and mechanical behavior - Maier, Verena; Hausöl, Tina; Schmidt, Christian; Böhm, Wolfgang; Hung Nguyen,; Merklein, Marion; Höppel, Heinz Werner; Göken, Mathias (Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science, 2012)
Aluminum alloy AA6016 was accumulative roll bonded up to eight cycles and investigated regarding formability by bending tests. Due to the limited bendability of accumulative roll bonding (ARB) processed materials, a tailored laser heat treatment was performed along the bending edge before forming. This tailored laser heat treatment causes a local recrystallization and recovery of the bending samples at the deformation zone, which locally increases ductility and allows higher bending angles achievable with lower forming forces. Between the recrystallized heat treated zone and the unaffected ultrafine-grained (UFG) base material, a gradient in grain size with a bimodal region is formed. This observed microstructural profile is confirmed by local mechanical testing measuring the hardness and strain rate sensitivity by nanoindentation techniques.
WW1::947

Technical, Economical and Ecological Potentials of Electrified Roads - Franke, Jörg; Weigelt, Michael; Kneidl, Maximilian; Masuch, Michael; Kühl, Alexander (Wiener Produktionstechnik Kongress 2022, 2022)

Technical Modelling Approach for Spatial Integrated Optomechatronic Products - Zeitler, Jochen Tobias; Reitberger, Thomas; Reichle, Andreas; Backhaus, Carsten; Lindlein, Norbert; Franke, Jörg (Procedia CIRP, Volume 84, 2019)
In the age of digitalization, the amount of data generated and transferred continues to increase dramatically. To increase the usability of this data it must be accessible with sufficient transmission bandwidth. Optical signals are already being used for transmitting data over long distances and high bandwidths, as this enables fast and low-loss data transmission. This trend is now also continuing in smaller scales of data transmission. Consequently, even highly integrated electrical circuits must be supported with optical components. Therefore, completely new research approaches for the product development of spatially integrated optical waveguides are necessary. The polymer-based aerosol jet printing represents a promising method to print optical waveguides on 3D circuit carriers. For this reason, the Research Group for Module Integrated Bus Systems deals with topics related to product development and production of such systems. A focus is to customize the design and associated modelling tasks accordingly. Thus, it is essential to create methodical approaches for a digital representation of waveguides and their production processes in order to map the physical behavior and to predict their manufacturability. Current studies show that integrated engineering approaches with removed boundaries among engineering domains are preferable to traditional engineering approaches. Consequently, novel engineering tools are needed for modelling the geometric as well as the physical properties of optical waveguides with the possibility to integrate specific design rule checks. The presented modelling approach in this paper provides/supports the creation of exact digital models without discontinuities through unnecessary interfaces. This article presents a method for a powerful computer-aided modelling environment that enables the design of models that are capable of representing and validating logical relationships among optoelectronic networks, but also considers challenges resulting from spatial geometric characteristics as well as restrictions from manufacturing and physic
Keywords: Computer aided design (CAD); Product development; Optomechatronics

Technische Erfassung der Energieflexibilität und deren Umsetzung in der Produktion - Popp, Richard; Liebl, Corinna; Zäh, Michael F.; Atabay, Dennis; Wagner, Ulrich; Buderus, Julian; Kohl, Johannes; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
This article presents an overview of the technical possibilities of production facilities to alternate their energy demand depending on outer circumstances, arisen from the research network FOREnergy. It is shown how key activities can be identified by measurement to establish a flexible energy demand. Different approaches using the examples of production machines and building services show a process-safe implementation of flexibility measures using intelligent storage and communication systems.
CRIS-Team Scopus Importer:2023-03-07

Techno-economic analysis of battery storage systems and hydrogen- based storage systems as an alternative to grid expansion in the medium voltage grid in Germany - Teske, Franz; Schubert, Jano; Fehrle, Adrian; Funk, Felix; Franke, Jörg (AIMS Energy, 2023)
The decentralization of the energy system in Germany is leading to enormous investments in grid expansion, as the current regulation creates an obligation to expand the power grid to eliminate bottlenecks. Meanwhile, opportunities to leverage grid-friendly control of storage systems are neglected to alleviate the need for investment. For this reason, it is necessary to investigate intelligent alternatives to grid expansion, such as storage systems, to efficiently integrate distributed technologies into the power system and reduce the need for grid expansion. In this work, two representative configurations of a medium voltage grid in Germany are developed for the years 2022 and 2050, and different storage systems are compared economically with the grid expansion in a model-based simulation. Hydrogen storage and battery storage were chosen as storage systems. The results show that grid expansion is the least expensive option if only the grid expansion costs are included in the analysis. However, if additional uses for the storage systems are considered, the battery storage systems are more economical. While in the scenario for 2050 the grid expansion causes costs of approx. 56,000 EUR per year, revenues of at least 58,000 EUR per year can be achieved via the revenue opportunities of the battery storage, representing a 3.5% margin. Heat extraction, arbitrage trading, and avoidance of grid expansion in superimposed grid levels were integrated as additional revenue streams/sources. A robust data basis and cost degressions were assumed for the simulations to generate meaningful results. Overall, hydrogen storage systems are economically inferior to battery storage systems and grid expansion for this use case. The results demonstrate the complexity of analyzing the trade-offs in terms of storage as an alternative to grid expansion as well as the opportunities presented using battery storage instead.
CRIS-Team WoS Importer:2023-05-05

Techno-Economic Comparison of Trading Agents for Renewable Energy Communities - Teske, Franz; Funk, Felix; Fehrle, Adrian; Franke, Jörg (IEEE, 2022)
The expansion of renewable energy sources and the decentralization of the European energy system will be driven by Renewable Energy Communities (RECs). These local aggregations of independent prosumers were introduced in 2018 and are characterized by peer-to-peer trading among their members. However, the design of this local energy trading can vary widely in terms of coordination of power transfer, incentive schemes, and members' options for action. In this paper, the power transfers of RECs are coordinated in a market-oriented manner. For this purpose, trading agents with different bidding strategies that consider the specific characteristics of RECs in their trading decisions are developed and compared from a technical and economic perspective. The results show that the trading agents with an intelligent bidding strategy achieve economic advantages over non-intelligent trading agents and no trading agents. It is also shown that economic optimization is not necessarily accompanied by a reduction in peak load.<br

Techno-Economic Evaluation of Strategic Solutions to Extend the Range of Electric Vehicles - Weigelt, Michael; Mayr, Andreas; Masuch, Michael; Batz, Kilian; Franke, Jörg; Bican, Peter; Brem, Alexander; Russer, Johannes A.; Russer, Peter (8th International Electric Drives Production Conference (EDPC), 2018)

Techno-Economic Evaluation of Technological Alternatives to Extend the Range of Electric Vehicles - Weigelt, Michael; Mayr, Andreas; Kühl, Alexander; Batz, Kilian; Bican, Peter; Russer, Johannes A.; Russer, Peter; Franke, Jörg (5th Annual Conference on Electric Roads & Vehicles, 2018)

Technologieorientierte Softwarebewertung zur Unterstützung von Beschaffungsentscheidungen - Bodendorf, Frank; Hollweck, Barbara; Franke, Jörg (Controlling, 2020)
Die Digitalisierung im Automobilbau steigert die Bedeutung der Softwarebeschaffung. Der Einkauf benötigt dabei geeignete Softwarebewertungsmodelle, um bei den Verhandlungen mit Lieferanten die Preistransparenz zu erhöhen. Es wird ein neues Modell vorgestellt, das traditionelle Kostenanalysemethoden mit einer wertorientierten Betrachtung, insb. der Technologieattraktivität, kombinier
Keywords: Automotive Industry; Cost Analysis; Procurement; Software Evaluation; Technology Evaluation

Technologies and processes for the flexible robotic assembly of electric motor stators - Kühl, Alexander; Furlan, Stefan; Gutmann, Joschka; Meyer, Manuel; Franke, Jörg (2017 IEEE International Electric Machines and Drives Conference (IEMDC), 2017)

Technology-Based Lifecycle Assessment of Software Components in Automotive Product Planning - Bodendorf, Frank; Franke, Jörg (Advances in Intelligent Systems and Computing, 2020)
Digitalization in combination with shorter product life cycles, driven by constantly changing customer demands, results in an increasing innovation pressure on automobile manufacturers (original equipment manufacturers, OEMs). The OEM’s R&D department is in charge of integrating innovative software for a variety of components and functions in the digital car of the future. In order to assess the value of software components in car design and development, new evaluation approaches for software technologies are needed, as traditional planning methods for physical parts cannot easily be transferred to immaterial goods like software. A new model is introduced, which follows a value-oriented approach, based on the technology attractiveness of software. It helps to determine the added value structure of technologies incorporated in software components over the whole lifecycle and, thereby, to increase the sustainability of software in the planning process of a new car.
CRIS-Team Scopus Importer:2020-07-31
Keywords: Automotive industry; Car software; Lifecycle management; Product planning; Technology analysis; Value engineering; Value estimation

Tensegrity-Inspired Joint Can Protect from Impacts by Isolating - Walter, Jonas; Rothfischer, Lukas; Stierstorfer, Richard; Nemoto, Takeru; Franke, Jörg; Reitelshöfer, Sebastian (Mechanisms and Machine Science, 2023)
Cable-driven parallel robots are known for their highly dynamic motions. At the same time, tensegrity robots are considered to be robust due to their intrinsic compliance. In a previous work, it was shown that a cable-driven joint with a tensegrity-inspired design allows fast rotations. The question remains whether such a joint is not only fast, but could also protect its base link from impacts due to its special design. In this paper, it is shown that a tensegrity-inspired joint can protect from impacts by isolating. A hardware prototype of such a joint was loaded with a modal hammer. It was found that the joint isolates impact forces up to 83%, demonstrating its ability to effectively absorb and dissipate energy from external impacts. Putting the results in a more general context, such a joint, however, can be used not only (a) passively to protect a base link, but also (b) actively for high-speed motions of a follower link by pulling a lightweight mass with parallel attached and actuated cables. It is anticipated that this study could be a starting point for the creation of novel robotic kinematics, composed of conventional and tensegrity kinematics, to build fast and robust robots.
CRIS-Team Scopus Importer:2023-11-17
Keywords: Cable-Driven Joint; Impact Protection; Tensegrity

Testing and simulation of lifetime for wire bond interconnections with varying bond foot angle - Sippel, Marcel; Tan, Yi Fong; Schmidt, Ralf; Botazzoli, Pietro; Sprenger, Mario; Franke, Jörg (Microelectronics Reliability, 2024)
Ensuring sufficient reliability is one key aspect in the design process of a power electronic module. The wire bond interconnection to the semiconductor chip is often limiting the power cycling lifetime of the module. Increased packaging density as well as integration of additional components on module level can limit the available space for the wire bond layout. To enable proper “design for reliability” measures the layout parameters affecting the lifetime of the module have to be identified. In this paper, the rotation of the bond foot relative to the bond loop is identified as a significant factor that decreases lifetime. The resulting bond foot angle is evaluated for different power semiconductor chips by means of accelerated lifetime testing isolated from other design parameters as well as with application relevant designs, compounding multiple parameters relevant for the lifetime of the module. In order to further facilitate “design for reliability” by reducing the number of necessary design iterations a multiphysics simulation is set up. An applicable evaluation method for bond layout changes is identified and good correlation of the computed equivalent plastic strain to lifetime testing data is established. Additionally, the impact of operation conditions of the module based on the load current applied to the bond wires is evaluated numerically.
CRIS-Team Scopus Importer:2024-04-19
Keywords: Bond foot angle; Design for reliability; Multiphysics simulation; Power cycling; Wire bond layout

Test Methods and Influencing Factors for the Adhesion Strength Measurement of Metallized Structures on Thermoplastic Substrates - Kuhn, Thomas; Franke, Jörg (Proceedings of the 16th Electronics Packaging Technology Conference (EPTC), 2014)
The requirements that apply to mechatronic systems regarding integration density, functionality, and miniaturization are significantly increasing. In this context molded interconnect devices (MID) offer in many cases an appropriate solution due to their spatial design freedom and versatile possibilities for functional integration. Already today, the technology is used in a wide range of application fields. Especially in safety and security relevant systems, the reliability is a crucial aspect, which is highly influenced by the adhesions strength of the metallized structures on the substrate. However, general standards or guidelines for testing MID do not exist and conventional test methods are in most cases only limited suitable for determining the adhesion strength of the metallization on molded interconnect devices. In this paper, commonly used adhesion tests are presented and assessed regarding their suitability for their use in MID. Thereby, the new hot pin pull test is introduced in detail. Comparative investigations with conventional test methods show promising results concerning reproducibility and a low standard deviation. The impact of influencing factors on the test results, such as the temperature or the wetting of the test structures with solder illustrates the importance of testing standards.
Keywords: E|P; Elektronikproduktion; MID; Zuverlässigkeit

Tetrahedral and polyhedral mesh evaluation for cerebral hemodynamic simulation–a comparison - Spiegel, Martin; Redel, Thomas; Zhang, Yao; Struffert, Tobias; Hornegger, Joachim; Grossman, Robert G.; Dörfler, Arnd; Karmonik, Christof (Proceedings of the Annual International Conference of the IEEE Engineering in Medicine and Biology Society, EMBS, 2009)
Computational fluid dynamic (CFD) based on patient-specific medical imaging data has found widespread use for visualizing and quantifying hemodynamics in cerebrovascular disease such as cerebral aneurysms or stenotic vessels. This paper focuses on optimizing mesh parameters for CFD simulation of cerebral aneurysms. Valid blood flow simulations strongly depend on the mesh quality. Meshes with a coarse spatial resolution may lead to an inaccurate flow pattern. Meshes with a large number of elements will result in unnecessarily high computation time which is undesirable should CFD be used for planning in the interventional setting. Most CFD simulations reported for these vascular pathologies have used tetrahedral meshes. We illustrate the use of polyhedral volume elements in comparison to tetrahedral meshing on two different geometries, a sidewall aneurysm of the internal carotid artery and a basilar bifurcation aneurysm. The spatial mesh resolution ranges between 5,119 and 228,118 volume elements. The evaluation of the different meshes was based on the wall shear stress previously identified as a one possible parameter for assessing aneurysm growth. Polyhedral meshes showed better accuracy, lower memory demand, shorter computational speed and faster convergence behavior (on average 369 iterations less).
UnivIS-Import:2017-01-09:Pub.2009.tech.IMMD.IMMD5.tetrah_3

The Automated Evaluation of the Energy Efficiency for Machining Applications based on the Least Energy Demand - Kreitlein, Sven; Scholz, Michael; Franke, Jörg (The Automated Evaluation of the Energy Efficiency for Machining Applications based on the Least Energy Demand, 2017)

The development and validation of a segmented rotor design for electric motors in hybrid vehicle applications - Franke, Jörg; Albrecht, Thomas; Lamprecht, Erik; Hubert, Markus; Schneider, Michael (2014 International Symposium on Power Electronics, Electrical Drives, Automation and Motion, SPEEDAM 2014, 2014)
This paper presents investigations into the development and validation of a new segmented rotor design. A segmented rotor design avoids the significant waste of the precious electric steel material and therefore leads to cost reductions. For validation of the segmented rotor design, a finite element method simulation, tensile tests, centrifugal stress tests and iron loss measurements were carried out. The simulation results allow for determining of a segmented rotor design. The tensile and centrifugal test results further confirm the capability of the segmented rotor design for serial applications. The results confirm that the rotor design does not generate additional iron losses. © 2014 IEEE.
Keywords: electric mobility; iron losses; manufacturing processes; rotor segmentation

The Digital Twin Concept in Industry – A Review and Systematization - Sjarov, Martin; Lechler, Tobias; Fuchs, Jonathan; Brossog, Matthias; Selmaier, Andreas; Faltus, Florian; Donhauser, Toni; Franke, Jörg (2020)
The scientific discussion on the Digital Twin gained substantial momentum within the last couple of years. In the context of Industry 4.0, the Digital Twin in the broadest sense refers to the concept of a coupled virtual representation of a physical asset. The asset types may range from products and processes to whole production systems. Different authors offer a variety of interpretations on the actual nature of the Digital Twin, often defining it via implicit functional aspects rather than giving explicit definitions. At the same time, some authors use the term merely as a catchphrase, thus applying blur to this emerging paradigm. At this point, a comprehensive understanding as well as a unifying model of the Digital Twin are absent. This paper therefore provides a structured review of the body of relevant literature with the specific focus on finding explicit definitions of the term "Digital Twin" as well as stated models characterizing the Digital Twin concept. As a result, a relevance assessment provides the most important literature regarding the research questions. The found explicit definitions, being partly conflicting, are presented. Similar notions like Product Avatar and Digital Shadow are assorted accordingly. Further, depictions of Digital Twin models stated in the most relevant literature as well as derived Digital Twin purposes are provided. Thus, this paper extends the theoretical foundation, thereby setting a basis for future augmented Digital Twin modeling.<br
Keywords: Digital Twin; Industry 4.0; Definition; Structured Review

The future of short-range high-speed data transmission: printed polymer optical waveguides (POW) innovation, fabrication, and challenges - Reitberger, Thomas; Stoll, Thomas; Hoffmann, Gerd-Albert; Lorenz, Lukas; Neermann, Simone; Overmeyer, Ludger; Bock, Karlheinz; Wolter, Klaus-Jürgen; Franke, Jörg (Proceedings of SPIE, 2018)
One of today’s megatrends in the industrial environment is additive manufacturing. Faster prototyping, customized products like hearing devices, integrated functions like heatsinks and many other opportunities are offered by this technological development. The opportunity of using different materials and build up 3-D structures is virtually infinite. Another one is the digitalization of almost any product to build up a smart world. This trend leads to a tremendously rising amount of data to be transferred from one place to another. If a wireless transmission is not possible and if the distance is over 100 m glass fiber is the fastest and most secure way for these requirements. In case of most short-range applications up to 100 m primary copper cables or circuit paths are in use because the electrical data transfer is well known. The limited bandwidth of copper asks for new inventions to meet the demands of tomorrow. Regarding both megatrends, the solution for this upcoming bottleneck could be 3-D printed photonic packages. This paper shows a new and innovative way for the customized fabricating of short-range data transmission networks. By Aerosol Jet Printing (AJP) the so called polymer optical waveguides (POW), it is possible to build up 3-D printed light guiding structures with low attenuation on almost any three-dimensional surface. The main advantages of the here presented research are high flexibility, low weight and low costs. After three years of intensive studies the most important key facts (machine settings, geometry, performance) are summarized in this publication.<br

The Influence of Different Arrangements of Shallow Dimples on the Resistance of Plates Subjected to Relative Fluid Motion - Praß, Julian; Wannemacher, Hagen; Franke, Jörg; Becker, Stefan (Technische Mechanik, 2019)
Shallow dimples have long been a scientifically investigated topic to reduce the flow resistance of objects subjectedto overflow. Most of the investigations on the influence of dimples on flow resistance have so far been carriedout experimentally. Although the arrangements and flow conditions are often similar, different research activitiesconclude differently concerning the effect of the surface structures. This also leads to disagreement regarding thecauses of flow resistance reductions. In this paper, time-resolved Large Eddy Simulations on two different, alreadyexperimentally investigated setups of dimples have been carried out to better understand the effects of dimpleson the surface being subjected to relative fluid motion. In one case the dimples were examined in overlappingarrangement, in the other case in a non-overlapping arrangement. We were able to show that the formation ofstreaks near the surface significantly influences the local contribution to the flow resistance. For the overlappingarrangement, only a slight resistance reduction of 0.12 % was determined. For the non-overlapping arrangement,the mean resistance reduction was found to be 3.16 %. Regardless of the resistance reduction determined, a clearinteraction between longitudinal vortices near the plate and local contributions to flow resistance could be demon-strated. Since these longitudinal vortices are directly influenced by the dimples, it is very likely that an optimizedarrangement of the dimples, adapted to the flow conditions, can reduce the resistan
Keywords: drag reduction; passive method; macroskopic surface structures

The Least Energy Demand Method as Metric to Describe the Relative Energy Efficiency of a Product based on its Manufacturing - Kreitlein, Sven; Kupfer, Isabel; Scholz, Michael; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production, 2015)
This paper presents a calculation system for evaluating the energy efficiency of a product regarding its production. In order to evaluate the energy efficiency of the manufacturing of a product value-adding processes as well as auxiliary processes are taken into account. Furthermore, the energy consumption of the periphery, in total is included. Since the total value-added chain of a product usually is not located at only one company, the energy efficiency of the manufacturing of the bought-in parts must also be included. In a last step, the plant specific energy efficiency at the product level based on all plants that produce the observed product can be determined. The basic target is a comparability of the energy efficiency across products by derivation of significant KPI’s. The basis to derive possible saving potentials is he relative energy efficiency (REE), which is the quotient of the minimal energy demand and actually measured consumption. For this, it is required that the actually measured energy consumption is based on an independent basis of comparison. This is assured by the stepped least energy demand method, for a product, based on the process-related perspective level of the bottom-up approach.

The Least Energy Demand Method as unique tool to evaluate and rate the energy efficiency of the electric drives production - Kreitlein, Sven; Spahr, Michael; Utz, M.; Franke, Jörg (6th International Electric Drives Production Conference, EDPC 2016, 2017)
This paper evaluates a method for the assessment and evaluation of energy efficiency of the manufacturing process in the electric drive production as well as a corporate and cross-industry comparison. First, the system for the Least Energy Demand Method will be explained. The basic idea of the calculation is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the measured energy consumption [8]. The Least Energy Demand Method is subsequently extended with the calculation system to evaluate the relative energy efficiency (REE) of higher levels of perspective. The goal is a comparability of the energy efficiency across machines, plants, locations, companies and sectors through definition of significant key figures. The basis of the derivation of possible saving potentials is the relative energy efficiency [6]. The REE of a level of perspective is calculated on the basis of the REE value of the previous production level as well as according to weighting factors. On the basis of the calculation, as well as subsequent measurements within the company, optimization potentials [10] can be clearly described and traced back to their roots. These optimization potentials are based on exemplary trials presented for a chosen manufacturing chain of an electronic production area [5]. The system of the energy efficiency evaluation during the manufacturing process is applied in the production of stators for bike motors.
Keywords: Energy Benchmark; Energy efficiency; Least Energy Demand Method; Manufacturing strategy; Production; Relative Energy Efficiency

The LinKin System: A new robotic and universally applicable radiation therapy device - Ziegler, Christian; Franke, Jörg (2013 44th International Symposium on Robotics, ISR 2013, 2013)
This paper presents the LinKin System, a fundamentally new robotic radiation therapy device with six degrees of freedom. Because of its linear kinematics system design it has substantial advantages over common therapy devices. The highly flexible and universally applicable LinKin System opens a unique broad application range. Furthermore, due to its novel assistant functions it can be well-integrated into the clinic specific workflows. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Mechanisms and Kinematics; Medical Robots; Radiation Therapy

Theoretical benefits of powder-coating based insulation layers regarding copper fill factor in electric drives - Hofmann, Benjamin; Bickel, Benjamin; Bräuer, Philipp; Leder, Michael; Franke, Jörg (6th International Electric Drives Production Conference (EDPC), 2016)
Keywords: E|DRIVE

The power of knowledge: A literature review on socio-technical perspectives on organizational knowledge management - Ochmann, Jessica; Laumer, Sven; Franke, Jörg (Proceedings of the 2019 Americas Conference on Information Systems, 2019)
In a fast-moving world with complex organizational structures and geographic dispersion of employees, an efficient management of knowledge and related systems is crucial for an organizations’ competitive advantage. In this paper we examine social and technological aspects that influence how individuals can be motivated to share and create knowledge by conducting a systematic literature review. As a result, we present a holistic view on the social and technical perspectives of the organizations’ knowledge management thereby outlining the need for an integrated consideration of these two dimensions. Moreover, we place actual social developments and innovative technologies in the context of this research field and outline the need for future academic discussions
Keywords: Knowledge Management; Knowledge Management Systems; Socio-Technical-Systems; Literature Review

The Power of Technological Innovation - Franke, Jörg; Wasserscheid, Peter; Ihne, Thorsten; Lamp, Peter; Guldner, Jürgen; Zipse, Oliver (Road to Net Zero, 2023)
Achieving the urgent need for rapid decarbonization to meet the 1.5 °C target requires disruptive technological change. In the automotive industry, technological progress is closely linked to improved sustainability, and sustainability goals drive the need for technological innovation. However, new technologies in the mobility sector are fraught with uncertainties that challenge both original equipment manufacturers (OEMs) and their stakeholders, such as suppliers, customers, and policy-makers. Therefore, this chapter focuses on the technical, economic, and environmental evaluation of alternative powertrain concepts and the management of uncertainties associated with emerging technological innovation as part of the broader transition to net zero. Electric mobility plays a central role in the sustainability transition and is characterized by a high degree of variance. Battery electric vehicles (BEVs) are expected to dominate private transport in the future due to their greenhouse gas and pollutant-free operation and high efficiency. In addition to charging infrastructure, the technical challenges currently lie primarily in cell chemistry and power electronics. Advances in battery technology and infrastructure electrification will help eliminate the range problem in the future. Another important future fuel is hydrogen. One application is the fuel cell vehicle, which combines the advantages of a chemical energy carrier with high gravimetric energy density with those of an electrical energy converter. Hydrogen also plays an important role as an energy carrier for specific energy supply processes in manufacturing processes and simplifies the transport of regeneratively generated energy. In addition, hybrid vehicles are a transitional technology, and alternative fuel internal combustion engines can contribute to the decarbonization of the existing fleet and to specific applications. This chapter assesses the performance of alternative powertrains; highlights the interrelationship between powertrain systems, energy ecosystems, and sustainability goals; and identifies future research directions for electric and hydrogen mobilit
Keywords: Electromobility; Hydrogen mobility; Alternative powertrains; Energy ecosystem; Battery technology; Charging technology

Thermische Beurteilung von THT-Lötstellendesigns für die IPC-konforme Kontaktierung durch Selektivwellenlöten - Seidel, Reinhardt; Thielen, Nils; Voigt, Christian; Franke, Jörg (EBL 2020, 2020)

Thermische Simulation von Werkzeugmaschinen zur Verbesserung der Fertigungsgenauigkeiten: Thermal simulation of machine tools for the advancement of the production accuracy - Kühl, Alexander; Franke, Jörg (Integrationsaspekte der Simulation, 2010)
Keywords: E|DRIVE; E|P

Thermisch leitfähige Kunststoffe für eine kostengünstige Fertigung und erweiterte Funktionalität in der MID‐Technologie - Hörber, Johannes; Franke, Jörg; Ranft, Florian; Heinle, Christoph; Drummer, Dietmar (PLUS - Produktion von Leiterplatten und Systemen, 2010)
UnivIS-Import:2015-03-09:Pub.2010.tech.FT.FT-KT.thermi

Thermodynamic and theoretical-based modeling and assessment of an energy-efficient performance measurement system in the soldering process - Esfandyari, Alireza; Kreitlein, Sven; Schmidt, Elias; Franke, Jörg (2016 Electronics Goes Green 2016+, EGG 2016, 2017)
This paper presents methods for the assessment and evaluation of two energy efficiency strategies for the soldering process in the field of electronics production. The first method evaluates the electrical energy consumption performance through the energy value modeling in the production process level. In the second method, also other energy resources rather the electrical energy consumption is considered. This method assesses the quality of resource conversion in the soldering process in the product level. In this paper, firstly, the system of the least energy demand as crossbench reference value is explained. The basic idea of this calculation is the comparison and evaluation of electrical energy efficiency based on the ratio of the theoretically required energy consumption to the measured electrical energy consumption. In the second method, the model quantifies the resource consumption and qualifies this consumption using the exergy analysis method. Exergy efficiency is the fraction of the work potential of the heat that is converted to work, and it illustrates the quality of consumed resources during the soldering process. Transparency and comparison of these two methods derives the measures to analyze and improve the major energy saving potentials in the soldering oven technology.
CRIS-Team Scopus Importer:2023-03-07

Thermoelectric Printhead Cooler for a Stable Process and Curing Control in RTV-2 Silicone Additive Manufacturing by Direct Ink Writing - Gugel, Lukas; Martin, Sina; Preis, Alexander; Franke, Jörg (Procedia CIRP, 2023)
The direct additive manufacturing, such as Direct Ink Writing (DIW), of silicone parts holds cost and complexity advantages. However, for extruding strands of low viscosity heat curing silicone rubbers, a build plate temperature of up to 90°C is used, which comes with the challenge of early vulcanization inside the printhead. Thus, this paper presents a thermoelectric cooler for universal printheads. At a build plate temperature of 90°C it prolongates vulcanization by 198.5 % (∆tpot life = 508.8 s), which allows a reduction of print speed for higher quality. Additionally, the influence of external temperature is reduced and the viscosity can be controlled. <br
Keywords: Direct Ink Writing; Vulcanization; Silicone; Silicone rubber; Additive Manufacturing; Thermoelectric cooler; Viscosity

Thermoforming of planar polymer optical waveguides for integrated optics in smart packaging materials - Hoffmann, G. A.; Wienke, A.; Reitberger, Thomas; Franke, Jörg; Kaierle, S.; Overmeyer, L. (Journal of Materials Processing Technology, 2020)
The innovations in smart packaging will open up a wide range of opportunities in the future. This work describes the processing of additive manufactured and planar integrated polymer optical waveguides for use in smart packaging products. The previously published combination of flexographic and Aerosol Jet printing is complemented by thermoforming and thus creates three-dimensional integrated multimode waveguides with optical attenuation of 1.9 dB/cm ± 0.1 dB/cm @ 638 nm. These properties will be the basis to develop smart applications in packaging materials.
CRIS-Team Scopus Importer:2020-06-23
Keywords: Additive manufacturing; Integrated optics; Polymer optical waveguides; Printing; Smart packaging; Thermoforming

The Technological Transformation Process for Dynamic Capabilities in Business Operations - Bodendorf, Frank; Franke, Jörg (IEEE Transactions on Engineering Management, 2024)
Dynamic capabilities enable companies to react agilely to changing competitive or environmental conditions. However, there is a lack of understanding the influences of the technological transformation process. Therefore, in this article, we examine the interrelationships and influences that the technological transformation process and digital competencies have on dynamic capabilities. Following an empirically calibrated system dynamics approach, three simulation studies are conducted investigating the development of dynamic capabilities in technological change, the influence of digital competencies on dynamic capabilities, and the relationship between dynamic technological capabilities and the competitiveness of companies. The results show that the impact of technological transformation is changing the concept of dynamic skills and that digital competencies are becoming increasingly important in this context. Thereby, a positive relationship between the determinants of digital maturity and the concept of dynamic capabilities is discovered. In addition, competitive advantages for companies can be realized through the targeted training of dynamic skills.
CRIS-Team Scopus Importer:2024-02-16
Keywords: Digital competencies; dynamic capabilities; system dynamics; technological transformation

The way to a simple and environment-friendly production design of complex foam parts – innovative solutions for the polyurethane manufacturing industry - Heisler, Paul; Gick, Sascha; Franke, Jörg (Procedia Manufacturing Volume 17, 2018)
Keywords: release agent; foaming; polyurethanes; system engineering; production technology

Three-Dimensional and with a Fine Structure: 3-D Technology on the Rise - Goth, Christian; Kuhn, Thomas (Kunststoffe International, 2015)
Molded Interconnected Devices (MID) are three-dimensional electronic assemblies (3-D). Their strengths lie in the great freedom of design, the degree of miniaturization attainable and the resultant weight reduction as well as in integration of numerous functions. These mechatronic systems are used in a wide variety of applications such as automotive, industrial electronics, medical devices, telecommunications and sensor technology. The following article highlights a number of interesting 3-D MID (injection molded circuit carriers) components. It discusses the trends in the fields of application mentioned that have a significant effect on the development of the processes, the equipment technology and, above all, the materials for 3-D MID technology. These include the growing demand for finer circuit trace structures that are considerably below the current standard of 150 µm, the necessary heat distribution for LED applications in particular, a high reliability despite increasingly stringent environmental regulations and cost-effective system solutions comparable to conventional technologies (e.g. rigid and flexible circuit boards). Accordingly, materials development is focusing on the production of finer filler particles, heat-conducting materials or systems and qualification of alternative high-performance grades as technologically and economically interesting alternatives to the proven LCP (Liquid Crystal Polymer) grade Vectra E840i LDS from Celanese GmbH, Sulzbach, Germany. Besides thermoplastic materials, new developments in the field of injection moldable thermosets are being evaluated.
Keywords: E|P; MID

Three-dimensional pose estimation of deformable linear object tips based on a low-cost, two-dimensional sensor setup and AI-based evaluation - Fröhlig, Simon; von Fabris auf Mayerhofen, Maximilian; Meiners, Moritz; Franke, Jörg (Procedia CIRP, 2022)
Handling and processing rigid objects is a common task for industrial robots. However, regarding flexible objects, this task is considerably more complex because gravity and other external forces influence the shape of the objects. Moreover, especially deformable linear objects like cables can show a large deformation. Therefore, regarding the automation of handling and assembly processes with robots, it is crucial to determine the current state of the shape of the cables. Furthermore, to significantly reduce the engineering cost and time, we introduce a method for utilizing synthetic data and thus reduce data acquisition and preparation efforts. The basic approach of detection is separated into four steps. Firstly, object detection identifies and classifies cable tips from two two-dimensional pictures taken from different perspectives. Secondly, keypoint detection identifies the pixel defining the start and endpoint of the identified object class. Thirdly, a triangulation merges the evaluations of the single images with the geometrical arrangement of the setup. Finally, a correction calculation compensates systematic errors caused by the inexactness of the physical camera setup based on an initially performed calibration algorithm performed for each new physical setup. The results presented in this paper prove the feasibility and advantage of the approach and show the impact of different characteristics on the accuracy of the three-dimensional pose estimation.
CRIS-Team Scopus Importer:2023-03-07
Keywords: 6D pose estimation; deformable linear object; DLO

Toward a structured concept for purpose-driven modeling of a digital shadow in manufacturing - Reichenstein, Tobias; Koustas, Spyridon Georg; Roßner, Alexander; Meiners, Moritz; Franke, Jörg (Procedia CIRP, 2023)
The growing relevance of Industry 4.0-related technologies and the transformation toward service-oriented business models in manufacturing requires relevant, high-qualitative data. The digital representation of operation and manufacturing under a specific purpose is called a digital shadow (DS). Although this purpose represents the decisive factor between different digital shadows, its systematic determination has been addressed insufficiently. Therefore, this paper presents a systematic, purpose-driven modeling approach for the digital shadow supporting manufacturing companies in developing a data basis for applications. This approach is applied to a crimping machine as an example and will be optimized in future evaluations.<br

Towards a circular economy for electrical products: A systematic literature review and research agenda for automated recycling - Bründl, Patrick; Scheck, Albert; Nguyen, Huong Giang; Franke, Jörg (Robotics and Computer-Integrated Manufacturing, 2024)
The growing need for sustainable waste management, especially for electronic waste (e-waste), has gained attention due to its environmental and economic implications. Despite the technological evolution of electronic products, their short lifespan and frequent replacement have led to a surge in discarded equipment. In particular, e-waste is rich in valuable materials, often exceeding natural ores. The challenge lies in the recycling of complex products, such as electrical or mechatronic systems, which consist of different materials. In addition, many of these discarded products are shipped to low-cost countries, leading to environmental concerns and health risks for workers. This paper explores the potential of automating the recycling process to address these challenges. This systematic literature review examines the emerging field of automated recycling for electronic products, with a focus on the transition to a circular economy. The results show that the literature on automated disassembly is highly focused on intelligent scheduling strategies, object recognition, sorting, tooling, disassembly, and robotic solutions, with particular emphasis on robotic cell design, robot kinematics, and human-robot collaboration. This review makes a significant contribution to the growing academic discourse on automated recycling and the circular economy, while laying the groundwork for future research and innovation by postulating a comprehensive research agenda.
CRIS-Team Scopus Importer:2023-12-15
Keywords: Automation; Control cabinet; Disassembly; Electrical products; Mechatronic products; Recycling; Systematic literature review

Towards a Data-Driven Process Monitoring for Machining Operations Using the Example of Electric Drive Production - Kißkalt, Dominik; Mayr, Andreas; von Lindenfels, Johannes; Franke, Jörg (8th International Electric Drives Production Conference (EDPC), 2018)

Towards a Knowledge-Based Design Methodology for Managing the Complexity in the Integrated Product and Process Development of Electric Motors - Mayr, Andreas; Meyer, Alexander Wilhelm; Schäffer, Eike; Masuch, Michael; von Lindenfels, Johannes; Mössinger, Gero; Franke, Jörg (Advances in Production Research, 2018)

Towards an Inline Quality Monitoring for Crimping Processes Utilizing Machine Learning Techniques - Meiners, Moritz; Mayr, Andreas; Kuhn, Marlene; Raab, Bernhard; Franke, Jörg (2020 10th International Electric Drives Production Conference, EDPC 2020 - Proceedings, 2020)
With the increasing demand for electric vehicles, automobile manufacturers and suppliers need to adjust their value chains to meet future requirements. In wire harness assembly, which is part of the production of vehicle electrical systems, the joining of wires and connecting elements, usually realized by crimping, is one of the most complex and quality- critical processes. For quality assessment, the crimp height and pull-out force are measured as primary quality criteria. In the context of the increased safety requirements of autonomous driving, monitoring the crimp connections should be automated, holistic, and in real-time for each wire-crimp connection during production. However, the high complexity of internal and external influences as well as the variety of crimp connections complicates the operation of conventional process monitoring systems based on hard-coded criteria. In this context, data- driven approaches using the methods of artificial intelligence are moving into focus. The emerging development of information technology opens up new perspectives for process monitoring systems with inherent intelligence. To provide a proof of concept for an intelligent process monitoring, in this paper experiments are carried out on a crimping station, provoking different types of error conditions. The resulting dataset is then analyzed using deep learning. Finally, a comparison of the approaches shown is carried out, followed by an outlook on future research activities.
Created from Fastlane, Scopus look-up
Keywords: artificial intelligence; autoencoder; crimping; deep learning; machine learning; process curve; quality control

Towards an inline quick reaction system for actuator manufacturing using data mining - Sand, Christian; Kunz, Sabrina; Hubbert, Henning; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Large-scale production lines aim to realize 0 ppm defects. This is getting more and more complicated, due to all the so far achieved process optimizations. However, our research showed that a huge amount of unpredictable disturbance variables influences production systems, which promote defects. Here, the modelling of every single influence like temperature, machine condition, tool wear and quality of supplied parts is almost impossible, regarding a fully automated assembly line for actuators. Yet conventional methods for process optimization like Six Sigma, Kaizen, etc. usually focus on single processes and are not suited for quick reactions when disturbances occur during manufacture. Therefore, we created and evaluated a novel method based on data mining. To speed up failure detection, process data and testing results as well as batch information and new methods are required. This paper introduces an inline anomaly detection system to automatically highlight critical conditions with very low delay. Here, three independent systems analyze the data in order to detect jumps and outliers of process values and to find an anomalous distribution of defective parts within processes. For further investigations of detected malicious conditions an efficient root cause analysis for a whole production line including assembly and quality processes is introduced, which uses clustering and decision trees. Based on the detected anomalies of the system, we propose cluster algorithms to discover complex combinations of malicious process influences on the quality of the final product.
CRIS-Team Scopus Importer:2023-03-07
Keywords: anomaly detection; cluster analysis; data mining; decision trees; fast reaction system; jump detection; magnetic actuators; outliers; process optimization; root cause analysis

Towards an intelligent linear winding process through sensor integration and machine learning techniques - Mayr, Andreas; Kißkalt, Dominik; Lomakin, Alexander; Graichen, Knut; Franke, Jörg (8th CIRP Global Web Conference – Flexible Mass Customisation (CIRPe 2020), 2020)

Towards an intelligent straightening system for flat enameled copper wire: problem statement, review of related work, and basic concept - Mayr, Andreas; Baader, Marcel; Raffin, Tim; Riedel, Andreas; Franke, Jörg (Procedia CIRP, 2022)
Enameled copper wire is a crucial material for the production of modern electrical machines. With the advent of hairpin windings, copper wire with rectangular cross-section is gaining importance. Being delivered on coil carriers, the wire is subject to initial curvatures which must be leveled out before further processing. Since common straightening systems are set manually and not controlled automatically due to missing sensor feedback, the straightening process is very susceptible to material-related deviations. After providing an in-depth problem statement, this paper gives a structured overview of related approaches and derives a basic concept for the intelligent straightening of flat enameled copper wire.<br

Towards a Real-Time Environment Reconstruction for VR-Based Teleoperation Through Model Segmentation - Kohn, Sebastian; Blank, Andreas; Puljiz, David; Zenkel, Lothar; Bieber, Oswald; Hein, Björn; Franke, Jörg (Proceedings of 2018 IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS), 2018)
Over the next few years, more and more autonomous mobile robot systems will find their way into modern shop floors. However, it will be necessary to provide human-machine interfaces for interventions in unexpected situations like system deadlocks,algorithm failures or inabilities. Using virtual or mixed reality-technologies, multi-modal teleoperation offers potential for being a suitable human-machine interface. Essential challenges in this field are, among others, a real-time remote control, a time-efficient and holistic environment detection using multiple sensors, a noise-reduced visualization of sensor-data,and capabilities of object recognition. This paper summarizes research results regarding an architecture capable of a near realtime, interoperable an operator-supporting teleoperation. The focus of this paper is on a method to efficiently process and visualize point-clouds to meet high frame rate demands of virtual reality applications. To provide near real-time feedback of the robot and its environment over large distances, the presented method is capable to segment known objects from unknown objects to reduce bandwidth requirements. The results of this paper were evaluated using a industrial articulated robot arm for teleoperation via a long distance UDP/IP communication.<br
Keywords: Teleoperation; Augmented Virtuality; Real-Time Environment Reconstruction; Model Segmentation

Towards a Smart Electronics Production Using Machine Learning Techniques - Seidel, Reinhardt; Mayr, Andreas; Schäfer, Franziska; Kißkalt, Dominik; Franke, Jörg (2019 42nd International Spring Seminar on Electronics Technology (ISSE), 2019)
High quality and low costs are main drivers in electronics production. Regardless of the application, the trend towards batch size 1 heavily challenges current production systems. With higher data availability, the application of machine learning (ML) has great potential for the future of electronics production. Therefore, this paper gives an overview about exemplary investigations of ML techniques in the assembly of surface mount devices (SMD) and shows the need for a systematic proceeding when searching for profitable ML use cases. In doing so, a process-oriented methodology for the identification of ML use cases is derived, paving the way towards a smart electronics production.<br
Keywords: Electronics Production; Smart Factory; Machine Learning; Data Analytics; Production Data

Towards a Software System Providing Knowledge about Energy and Resource Efficiency Potentials within the Product and Process Development of Electric Drives - Mayr, Andreas; Meyer, Alexander Wilhelm; Masuch, Michael; Braun, Andra; Franke, Jörg (Applied Mechanics and Materials, Vol. 882, 2018)

Towards a Synthetic Tissue Model of the Lower Urinary Tract - Preis, Alexander; Merkl, Christina; Miralles, Paula; Heer, Svenja; Benke, Elisabeth; Reitelshöfer, Sebastian; Martin, Sina; Rieker, Ralf; Franke, Jörg (Proceedings of the 16th International Joint Conference on Biomedical Engineering Systems and Technologies BIOSTEC - (Volume 1), 2023)
The development of medical devices often depends on in vivo studies to validate the proper functioning of the products. These trials provide ethical as well as economic challenges, which can be partially addressed by the usage of realistic synthetic tissue models that replicate human anatomy and the corresponding properties of the biological tissue. In this work, a silicone-based model with a fiber structure and a PVA-based model that exhibits fabrication-induced anisotropy are presented in the special context of the lower urinary tract. The analysis of the materials in the uniaxial tensile test shows the anisotropic and viscoelastic properties of the materials. Furthermore, the anatomical model of the lower urinary tract shows expected deformation in simulation as well as in the real silicone model. Additionally, a suitable artificial urine according to ISO 20696 is shown for use with the model. First experiments to change the pH of the artificial urine are successfully conducted.<br
Keywords: Anatomical Model; Urology; Lower Urinary Tract; Urinary Bladder; Urethra; Artificial Urine

Towards “Design for Interoperability” in the context of Systems Engineering - Sjarov, Martin; Kißkalt, Dominik; Lechler, Tobias; Selmaier, Andreas; Franke, Jörg (Procedia CIRP, 2021)
In product development, early decisions made within the requirements specification and design phase have significant impact on overall functionality, quality and lifecycle cost of the product. In Systems Engineering, these oftentimes iterative design phases are steered by underlying development models, providing processes, guidelines and best practices. One family of guidelines are the “Design for X” (DfX) tools or principles. In the development of mechatronic systems e.g. production systems, traditionally the mechanical, electric and software domain are to be distinguished. Over time, driven by trends of digitalization, communication and interconnection of systems, the product innovation and thus the required development effort has been shifting from the mechanical domain towards the software domain. The question of system interoperability thereby is of a fundamental nature. This is especially relevant within the current paradigms of Industry 4.0 and the Digital Twin. To reflect the growing importance of interoperability (i.e. the ability of systems to purposefully interchange interpretable information) as a requirement for the product within the design phase of technical systems, this paper introduces “Design for Interoperability” (DfIOp) as a new DfX principle. First, this is motivated by the ever-growing importance of information technology for current and future products. Then, the main contribution of the paper is the combination of the state of the art in the research domains of DfX, interoperability, Systems Engineering and Industry 4.0. Consequently, DfIOp will be presented, including a systematization model as well as a first method for its implementation. Further contemplation on DfIOp shows, that it enables derivative principles such as “Design for Data Analytics” and “Design for Digital Twin”. In future research, the underlying models as well as methods of DfIOp are to be further detailed and integrated into the research context.<br
Keywords: Design for Interoperability; Design for X; Interoperability; MBSE; Industry 4.0

Towards identifying and linking data silos along the software life cycle - Martens, Benedikt; Petho, Pal; Holm, Timo; Franke, Jörg (ICCSE 2021 - IEEE 16th International Conference on Computer Science and Education, 2021)
Software is of increasing importance in all industries and it's efficient creation an important factor in the success of corporations. Using the data generated during the entire software life cycle to create understanding and derive actionable insights, decisions can be made on a factual basis. One of the key requirements to making these objective decisions possible is the collection, composition, and communication of data to the correct stakeholders. To further these goals, the most complete collection of data artifacts available in the software life cycle is presented. These are abstracted to be independent of programming language, development process and toolset. As value is derived from the connection of entities, a set of possible connections is introduced as well as challenges and solutions in their creation discussed. The theoretical observations, and results are verified in the context of a large development organization with more than a thousand developers working from multiple global locations. Our results show that the combination of multiple data sources and their systematic composition are paramount to deriving value from life cycle data in large corporations.
CRIS-Team Scopus Importer:2021-11-19
Keywords: Corporate learning; Decision making; Empirical software development; Software artifacts; Software life cycle

Towards Knowledge Graphs for Industrial End-To-End Data Integration: Technologies, Architectures and Potentials - Sjarov, Martin; Franke, Jörg (11th Congress of the German Academic Association for Production Technology (WGP), 2021)
Knowledge Graphs can be characterized as a set of semantically linked information artifacts. One of their possible applications is to enable the integration of heterogeneous data sources: A task becoming increasingly important within industry to obtain end-to-end transparency for complex process chains. There, they can further serve the data for automated machine learning algorithms to operate on. This paper at first elaborates on the definition and characteristics of Knowledge Graphs and data integration. Then, the underlying semantic architectures as well as the corresponding information technology standards are collected. Additionally, first industrial applications in the context of Knowledge Graph-based data integration are presented. The insights are compared with an exemplary custom implementation. Lastly, the findings are assessed for their potential to enable end-to-end data integration and furthermore to provide the basis for future machine learning applications to operate on.
Keywords: Knowledge Graph; Data Integration; Industry 4.0

Towards Material-Batch-Aware Tool Condition Monitoring - Lutz, Benjamin; Howell, Philip; Regulin, Daniel; Engelmann, Bastian; Franke, Jörg (Journal of Manufacturing and Materials Processing, 2021)
In subtractive manufacturing, process monitoring systems are used to observe the manufacturing process, to predict maintenance actions and to suggest process optimizations. One challenge, however, is that the observable signals are influenced not only by the degradation of the cutting tool, but also by deviations in machinability among material batches. Thus it is necessary to first predict the respective material batch before making maintenance decisions. In this study, an approach is shown for batch-aware tool condition monitoring using feature extraction and unsupervised learning to analyze high-frequency control data in order to detect clusters of materials with different machinability, and subsequently optimize the respective manufacturing process. This approach is validated using cutting experiments and implemented as an edge framework.
CRIS-Team WoS Importer:2022-01-14

Towards the Digital Factory Twin in Engineer-to-Order Industries: A Focus on Control Cabinet Manufacturing - Stoidner, Micha; Bründl, Patrick; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (Advances in Production Management Systems. Production Management Systems for Responsible Manufacturing, Service, and Logistics Futures, 2023)
Digital transformation poses a challenge for small and medium-sized enterprises (SMEs) with an Engineer-to-Order (ETO) production characterized by a low-variant and low-volume manufacturing philosophy. This article aims to examine the role of a digital factory twin and material flow simulation to increase value creation in ETO production. The study follows a structured approach including a literature review, on-site process analysis, and simulations to determine the optimal production process design. The focus of qualitative and quantitative findings is on the control cabinet manufacturing as an important sector in Germany representative for ETO production. The findings comprise a novel definition of the digital factory twin (DFT), implementation of a simulation model and integration of lean manufacturing principles to optimize ETO production of control cabinets. This study makes a valuable contribution to the development of the DFT and illustrates the successful implementation of simulation as well as lean manufacturing principles.<br
Keywords: Control Cabinet; Digital Factory Twin; Engineer-to-Order; Material Flow Simulation

Track and Trace: Integrating static and dynamic data in a hybrid graph-based traceability model - Kuhn, Marlene; Kaminski, Erik; Franke, Jörg (Procedia CIRP, 2022)
In smart manufacturing, an increasing amount of heterogeneous data inputs need to be integrated into a holistic traceability model. One key challenge is the coherent mapping of dynamic and event-based sensor data for real-time tracking purposes with static data, which are mostly needed for retrospective tracing purposes. In this research, we develop a graph-based traceability model, which integrates static and dynamic data sub-models in one connected traceability graph. For an automotive use case, the novel traceability model is implemented and tested using a hybrid architecture based on the graph database Neo4j and the event engine Apache Kafka.
CRIS-Team Scopus Importer:2022-12-09
Keywords: data model; graph; ICT architecture; smart manufacturing; traceability

Trustworthiness of machine learning models in manufacturing applications using the example of electronics manufacturing processes - Seidel, Reinhardt; Schmidt, Konstantin; Thielen, Nils; Franke, Jörg (Procedia CIRP, 2022)
The design phase of products decides about a large portion of their costs. Both applied manufacturing technologies and systems are ultimately defined by the products that have to be assembled. Due to global trends towards e-mobility and regenerative energy, electronic printed circuit boards with high copper content and mixed SMT/THT assembly is the predominant assembly scenario. This leads to thermally challenging soldering operations in THT-soldering as high copper masses dissipate the required heat and no reliable manufacturability check is available. Consequently, in electronic manufacturing complex thermal processes have still to be defined in iterative experimental steps. Reliable models have great potential to reduce time-to-market and scrap during new product introduction. Future manufacturing systems require infrastructure that allows manufacturability checks in the early design phase and automatically provides process programs on the shop floor once the design is finished. However, the lack of availability, long-term experience and consequently trust in automatically, by artificial intelligence generated and optimized process programs, blocks the realization and hinders further productivity gain. In this paper, an ML audit methodology is suggested that mitigates this lack of trust by providing physically plausible prediction series and quantitative risk assessment to the user. This complements typical evaluation scores and adds the model behavior in the process context and transmits a sense of transparency. A neural network is trained with an augmented dataset, exemplary for the prediction of the hole fill in mini wave soldering process. The model is then used to predict series of predictions for increasing soldering time and temperatures comparable to design of experiments. The resulting time versus hole fill plots helps the operator understanding the behavior of the model and thus, demonstrate the potential benefit of this approach to the entire manufacturing site.
Created from Fastlane, Scopus look-up
Keywords: Barrel fill; Design for manufacturing; Fontain soldering; Lead-free; Selective wave; Through hole technology; Transperent artificial intelligence

Typisierung von Netzwerkeffekten für digitale Plattformen in der produzierenden Industrie - Hartner, Fabian; Löwen, Ulrich; Franke, Jörg (Vorausschau und Technologieplanung 16. Symposium für Vorausschau und Technologieplanung, 2021)
In the business-to-consumer (B2C) market, in the last few years digital platform business mod- els have been able to successfully establish themselves and become part of our everyday lives (e.g., Uber, Amazon). In the context of the digitalization of products, production systems and processes, the importance of digital platforms is also increasing in the industrial business-to- business (B2B) market. Network effects, which arise when the number of users has an influence on the value of other actors, are named as a decisive mechanism for the success of platform business models. Previous studies focused on successful platform examples from the B2C mar- ket. A detailed investigation and differentiation of the effects occurring in the manufacturing industry is currently missing. In order to better illustrate the effects for industrial applications, nine practical examples were prepared in this paper using a value-oriented methodology. Based on this, they are analyzed for the influence of an increasing number of participants of the roles involved. Thereby, six different network effect types could be identified, which differ in their characteristics between certain roles and can be traced back to different value propositions. This typification should lead to a more detailed understanding of network effects in industrial value networks and thus support companies in using these effects in a focused approach building their platform business model.<br
Keywords: Digitale Plattformen; Netzwerkeffekte; Typisierung; Produzierende Industrie

UAS im Indoorbereich - Rechtliche und technische Einführung in die Nutzung von Indoor-UAS - Friedrich, Juliane; Lieret, Markus; Reich-Rohrwig, Leonhard; Seel, Andreas; Uslar, Wolfgang (2021)
Die UAS-Technologie gehört zu den bedeutenden technologischen Innovationen der vergangenen Jahre und eröffnet neue, bislang unbekannte Perspektiven in zahlreichen Anwendungsfeldern. In einigen dieser Anwendungsfelder wie bspw. bei der Fabriklayoutdigitalisierung oder dem innerbetrieblichen Materialtransport konnte die Verwendung von UAS bereits erfolgreich getestet und validiert werden. Der aktuelle technische Entwicklungsstand von UAS für Flugregelung, Kollisionsvermeidung und Flugleistung lässt grundsätzlich den Einsatz im Produktionsbetrieb zu. Ungeklärt ist weiterhin, welche rechtlichen und somit auch versicherungstechnischen, technischen und betrieblichen Voraussetzungen von anwendenden Unternehmen für die Verwendung im Produktionsbetrieb geschaffen werden müssen. In diesem Whitepaper werden rechtliche und versicherungstechnische Fragen diskutiert. Anschließend wird eine technische und betriebliche Risikoanalyse vorgestellt, die um einen Maßnahmenkatalog für eine fachgemäße Einführung und Anwendung der UAS-Technologie ergänzt wird. Dabei werden mögliche Risiken betrachtet, auch wenn mit zunehmendem Automatisierungsgrad von UAS die Risiken durch Sicherheitsmechanismen und entsprechende Sensorik verringert werden können.<br

Umfelderkennung, Absicherung und lokale Bahnplanung - Teilprojekt 2 - Blank, Andreas; Hiller, Markus; Heuss, Lisa; Roder, Sebastian; Thielecke, Jörn; Franke, Jörg (Abschlussbericht: FORobotics - mobile ad-hoc kooperierende Roboterteams; Aktenzeichen AZ-1225-16, Förderzeitraum 1.1.2017-30.6.2020, Berichtszeitraum: 1.1.2017-30.6.2020;, 2021)
Im Kapitel adressiert werden die im Forschungsprojekt FORobotics erforschten autonomen Fähigkeiten der eingesetzten mobilen Roboter und Manipulatoren sowie die hierfür erforderliche sensorische Wahrnehmung, Sensordatenfusion, Interpretation der Sensordaten und die Umweltmodellierung. Ebenso werden die notwendige lokale Bewegungsplanung der FORobotics mobilen Plattform und der integrierten Knickarmroboter beschrieben. Im Rahmen des Teilprojekts werden zudem entwickelte Absicherungskonzepte sowie deren Evaluation am Gesamtdemonstrator dargelegt. Auch adressiert werden Forschungsfragen zur geeigneten Vernetzung der Betriebsmittel. Bezüglich des Use Case und des FORobotics Gesamtdemonstrators wurden in enger Zusammenarbeit mit dem Demonstrator-Teilprojekt TP D, die folgenden Use-Case-relevanten Fähigkeiten im Forschungsprojekt erschlossen und bereitgestellt: die sensorische Wahrnehmung der Plattformumgebung sowie die Umfelderkennung und -Modellierung auf Basis einer möglichst optimalen Sensorkonfiguration, das zweckmäßige Bewegen der Plattformen und Roboter des Demonstrators für den Transport, zur Handhabung und Montage von Komponenten sowie allgemein zur Aufgabenerfüllung, die Absicherung der Roboter entlang der verschiedenen Use-Case-Szenarien sowie die Entwicklung und Ausgestaltung der Kommunikation zwischen den Entitäte
Keywords: FORobotics; Mobiler Roboter; Umfelderkennung; Umweltmodellierung; Absicherung; Bahnplanung; Navigation

Universal Fine Interpolation Algorithms for Accuracy Improvements of Industrial Robots - Buschhaus, Arnd; Franke, Jörg; Krusemark, Stefan; Karlidag, Engin (IEEE 8th International Congress on Ultra Modern Telecommunications & Control Systems, 2016)
Keywords: B|Mech

Unlocking the potential of digitalization and automation: a qualitative and quantitative study of the control cabinet manufacturing industry - Bründl, Patrick; Stoidner, Micha; Bredthauer, Jens; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (Production & Manufacturing Research, 2024)
This paper investigates the German control cabinet manufacturing industry, revealing its opportunities, challenges, and varying levels of digitalization and automation. The researchers employ cluster analysis, grouping companies into five clusters based on digitalization and automation, resulting in a new classification framework. This framework significantly improves the similarity level within each cluster by approximately 52.89 % compared to pre-existing models. While the levels of digitalization and automation vary greatly between the different clusters, skill shortages and supply chain problems are identified as potential development barriers to companies from all groups. To overcome these obstacles, the paper outlines key improvement areas based on data findings. This proposed classification can guide companies in assessing their digital maturity and pinpointing enhancement areas, emphasizing the necessity of adopting digitalization and automation for improved efficiency and market competitiveness.<br
CRIS-Team Scopus Importer:2024-02-02
Keywords: Control cabinet; digitalization; production automation; production strategies; engineer-to-order production

Untersuchung einer dezentralen Raumbelüftungsanlage mit Wärmerückgewinnung mittels zweifach teilbeaufschlagtem, mehrflutigem Querstrom-Reibungsventilator - Praß, Julian (Tagungsband zum 2. Green Factory Bavaria Kolloquium 2015, 2015)
Keywords: CFD; E|Home; Lüftung; Wärmerückgewinnung

Usage of Industrial Robots as Flexible Handling Devices Supporting the Process of Three Dimensional Conductive Pattern Generation - Buschhaus, Arnd; Franke, Jörg (11th International Congress Molded Interconnect Devices, 2014)
Due to their vast number of benefits, plenty of complex and miniaturized three dimensional molded interconnect devices are developed. One especially demanding process step during their manufacturing is the geometrical exact creation of the conductive pattern layout on the different substrates' faces. Therefore, sophisticated and flexible technologies like laser direct structuring or printing processes can be used, which are subject to multiple research activities, concentrating for example on coating materials or process parameters. An additional aspect is the necessity of providing a flexible and sufficiently accurate handling device, which three dimensionally moves the substrate relative to the process nozzle applying the coating material. For this task industrial robots could be used, which inherit multiple beneficial features. One main drawback of using this type of kinematic is their relative low absolute accuracy of a few hundred microns, which is not sufficient for moving the substrate during the process with the needed accuracy. To exploit the multiple advantages which accompany the usage of standard robots, in current research activities at FAPS institute a new approach is investigated, improving their accuracy in course of complex 3D-movements. In this work, modern optical sensor systems for online process monitoring and subsequent real-time robot control are used. By continuously supervising the conducting pattern generation progress, the actual process spot position on the substrate is determined. Subsequently, this information is used to continuously derive the robots actual position. Compared with target state values, geometrical offsets between actual state and target state are calculated. Considering this information during the process, a closed-loop control of the robot control is established and the robot's movement is corrected in real-time. Thereby, position deviations are compensated and an accurate application of the conductive pattern layout on the substrate is obtained. Improving the accuracy of conventional industrial robots and as a result qualifying them for supporting the conductive pattern generation of miniaturized 3D-MID products can greatly contribute to the MID technology. With their high flexibility of movement, the advantage of design flexibility of the 3D-MID technology can be even better exploited and hence more sophisticated 3D-MID products and applications will be possible in the future.
Keywords: B|Mech; Industrial Robot; 3D-MID; Structuring; Metallization; Sensor System

Use of automated in-line capable magnetic stray field measurement method for monitoring the value chain quality of magnetic circuits - Brela, Matthäus; Heyder, Andreas; Dietlein, Fabian; Markert, Johannes; Franke, Jörg; Hauenstein, R.; Wagner, R. (2014 International Symposium on Power Electronics, Electrical Drives, Automation and Motion, SPEEDAM 2014, 2014)
Common defects in electromagnetic actuators due to the manufacturing process are heterogeneous magnetic properties of the materials, cracks and defects in the magnetic materials and parasitic air gaps in and directly around the magnetic circuit. In most cases the error cause can be found in the value chain and is caused by material handling, assembling tolerances, environmental influences, etc. Considering the high global cost pressure, test systems must be adapted to the increasing complexity of the components in order to be able to detect defects completely in-situ and have smallest possible amortization period. For these requirements the novel and nondestructive measurement system is suitable to monitor and assure quality of magnetic actuators within the manufacturing process. The measuring principle is the characterization of electromagnetic actuators according to the detection of magnetic stray fields outside the magnetic circuit and the magnetic useful field inside the actuator that can be quantified by magnetic sensors. The intensity of the magnetic stray fields depends on the magnetic flux density and flux distribution in the magnetic circuit. Permeability variations for example caused by air gaps or internal stresses influence the flux distribution. In most cases they are caused by process parameter variations of the manufacturing and assembling. With the developed method this influences can be detected in an early stage of the manufacturing process automatically and in-line. This can lead to more competitiveness and long-term viability of the location. © 2014 IEEE.
CRIS-Team Scopus Importer:2023-03-07

Use of Printed Sensors to Measure Strain in Rolling Bearings under Isolated Boundary Conditions - Bartz, Marcel; Häußler, Felix; Halmos, Fabian; Ankenbrand, Markus; Jüttner, Michael; Roudenko, Jewgeni; Wirsching, Sven; Reichenberger, Marcus; Franke, Jörg; Wartzack, Sandro (Lubricants, 2023)
The knowledge of the operating conditions in rolling bearings in technical applications offers many advantages, for example, to ensure a safe operation and to save resources and costs with the help of condition monitoring and predictive maintenance procedures. In many cases, it is difficult to implement sensors to measure the operating conditions of the rolling bearing, for reasons such as inaccessibility of the mounting position or non-compliance with installation space neutrality, which influences the sensor on the measuring point. Printed sensors using a digital deposition process, which can be used in very narrow design spaces, offer advantages in this respect. So far, these sensors have not been established in rolling bearings, so there is potential for technical application. This paper discusses the fundamental advantages and disadvantages as well as the challenges of the application, and it demonstrates the feasibility under isolated boundary conditions by applying a printed strain gauge sensor to the outer ring of a cylindrical roller bearing NU210 in an experimental setup to measure the strain under load. In this setup, the outer ring is deformed by 2 mm under an increasing radial load using a hydraulic press, and the strain is measured. Both a commercial reference sensor and a FE-simulation are used to validate the measurement. The results show that an implementation using printed sensors as a strain gauge works successfully. The resulting challenges, such as measuring strain gradients and printing on curved surfaces, are finally evaluated, and an outlook for further work is given.<br
Keywords: rolling bearings; sensor-integrated machine elements; strain measurement; printed strain gauges; printed sensors

User Attitude Toward a Novel Smart Heating System - Kettschau, Anna-Katharina; Michl, Markus (Advanced Engineering Forum, 2016)
Keywords: Smart Home; Technology Use; User Acceptance; Attitudes toward technology

Valid Methodology for Using Discrete Event Simulation to Improve the Resource Consumption for the Manufacturing of Masonry Units - Donhauser, Toni; Rackow, Tobias; Hirschbrunn, Johannes; Schuderer, Peter; Franke, Jörg (48th CIRP International Conference on Manufacturing Systems, CIRP CMS 2015, 2016)
Owing to a high inflexibility of the factory layout, manufacturers of masonry units are bound to organizational adjustments seizing optimization measures. Regarding such plants, having a given complexity based on a rigid concatenation of heterogeneous sub-processes with heavy goods to be transported, conventional measures such as Lean Management principles involve great efforts in execution. Therefore, an IT solution for planning and controlling the operational processes is to be developed. This solution will be implemented through simulation-supported optimization to support dealing with a higher complexity and setting up a more resource-efficient manufacturing process. As a basis, a corresponding factory is mapped sufficiently accurate in every detail in a discrete event analysis (DEA) model. In this paper, a methodology, how to configure an arbitrary calcium silicate masonry unit (CS) plant in a simulation model, is presented for the first time. Relevant data is cataloged and modelling approaches for the controlling methods are pointed out. Special regard is paid to optimization measures at the crucial point of the transition from bulk material to piece goods, which has not been regarded yet in discrete event simulation modelling. The major aspect is a comparison of a unit-based approach and a variable-controlled approach, regarding the runtime. A case study follows conclusively, which aided in validating the methodology by simulating various scenarios. As a result, several strategic and operational optimization potentials were identified.
Keywords: Bulk material; calcium silicate masonry unit; Complexity management; Discrete event simulation; Piece goods; Production planning and control

Valuating and Pricing of Vehicle Generated Data as a Marketable Product in the Automotive Industry - Bodendorf, Frank; Meissner, Tobias; Franke, Jörg (Vehicular 2019: The Eighth International Conference on Advances in Vehicular Systems, Technologies and Applications, 2019)
Data-driven business models play a significant role in the digital transformation of traditional value-added industries. More and more existing and potential partners of automobile manufacturers show interest in the vehicle data generated by their products. However, there is still no monetary value assessment to support decisions regarding the release of data. Traditional pricing approaches for material goods are based on cost, margin, and volume. However, these bottom-up calculation approaches are not applicable to digital goods. The background to this is, among other things, the uncertainty about the potential sales volume, the difficulty of cost splitting,and the high cost degression per unit of digital goods. This paper provides decision support for selling data to third parties as an intangible product. It introduces a concept that allows to value data generated by a motor vehicle in order to determine potential prospects and prices for sale. The evaluation model developed supports the car manufacturer's negotiating position towards potential data buyers. <br
Keywords: Automotive Industry; Car Data; Business Model; Value Estimation

Valuation and pricing of software licenses to support supplier–buyer negotiations: A case study in the automotive industry - Bodendorf, Frank; Lutz, Manuel; Franke, Jörg (Managerial and Decision Economics, 2021)
Licensed standard software can be replicated millions of times at near zero cost for the supplier and poses immense challenges for purchasing and cost managers. A model is introduced to evaluate the appropriateness of software prices and thus to support the negotiation and decision process regarding suppliers. The model determines the “value to customer” of a software product using conjoint analysis and converts that value into a theoretical license price. In a case study coming from a large Original Equipment Manufacturer (OEM) it is shown that the developed conjoint model can successfully be used in practice and suggests realistic purchase prices.<br
Keywords: software valuation; pricing; conjoint analysis; purchasing; automotive industry

Vector Based Closed-Loop Control Methodology for Industrial Robots - Buschhaus, Arnd; Blank, Andreas; Franke, Jörg (ICAR 2015 - 17th International Conference on Advanced Robotics, 2015)
Improving the absolute accuracy of industrial robots is addressed by multiple activities of research institutes and robot manufacturers. Challenging in this context is an accuracy improvement of the robot during the movement. This is due to the necessity of providing time efficient and accurate target and actual state determination modules, an adequate data synchronization and a proper correction value calculation. This information can then be used to establish an online closed-loop control of the robot. One difficulty in such a system is to guarantee a smooth and steady movement despite the continuous inaccuracy compensation. To overcome this problem, recent research activities address a vector based control method. Thereby, the path planning is transferred to an external control unit, which performs all calculation steps. Based on this calculation, movement vectors synchronized with the interpolation cycle time of the robot are computed, continuously sent to the robot controller and brought to execution. These vectors include components, which describe the deviation between actual and target state and hence allow a compensation of the inaccuracies. Thereby, the robot is "pushed" along its optimal trajectory by small increments. Experiments already show good results, allowing a reactive control together with a smooth movement execution.
Keywords: Robot; Closed-Loop Control; Absolute Accuracy Improvement; Path Planning

Verfolgung von Bauteil- und Anlagentemperaturen in Produktionssystemen zur Energiesimulation bei thermischen Einflussfaktoren - Donhauser, Toni; Mayr, Andreas; Baier, Lukas; Franke, Jörg (ASIM 2019 - Simulation in Produktion und Logistik, 2019)

Vergleich alternativer Technologien zur Reichweitenverlängerung von Elektrofahrzeugen - Weigelt, Michael; Mayr, Andreas; Franke, Jörg (7th Conference on Future Automotive Technology (CoFAT), 2018)

Virtual Commissioning and the use of Extended Reality and Automated Testing: a survey of industry - Kunz, David; Barth, Martin; Franke, Jörg; Weber, Jacob (20. ASIM Fachtagung Simulation in Produktion und Logistik 2023, 2023)
Virtual Commissioning (VC) is seen as an important technology for managing the complexity of production systems. While it is demonstrated that VC can reduce commissioning time, defect rates and costs, the rate of industrial adoption is below expectations. In this paper, we present the results of a survey conducted to investigate the use, expectations, and barriers to the use of VC with an additional focus on Virtual Reality (VR), Augmented Reality (AR) and Test Automation (TA) in this context. The survey results reveal that just over half of the respondents use VC, albeit rarely to occasionally. Barriers to the use of VC are not technological. VR and AR technologies are used in many companies, but not frequently. The results indicate that the potential benefits of using these technologies are not clear enough to justify further investment in what is seen as a somewhat immature technology. TA can only be found in large companies. The main barriers are the amount of effort required to create and maintain automated tests and a general lack of know-how and resources. Respondents agree that all three technologies will become more important in the futur

Virtual Commissioning of 6 DoF Pose Estimation and Robotic Bin Picking Systems for Industrial Parts - Metzner, Maximilian; Weissert, Soeren; Karlidag, Engin; Albrecht, Felix; Blank, Andreas; Mayr, Andreas; Franke, Jörg (IFAC-PapersOnLine, 2019)

Virtual Commissioning – Scientific review and exploratory use cases in advanced production systems - Lechler, Tobias; Fischer, Eva; Metzner, Maximilian; Mayr, Andreas; Franke, Jörg (Procedia CIRP, 2019)
Virtual Commissioning increases quality and efficiency in production engineering whilst also decreasing required time. Even though it is a foundation for state-of-the-art production systems, it is not in widespread use yet. In this contribution, an overview of current scientific approaches and use cases for Virtual Commissioning is given. Furthermore, additional fields of interest are derived and detailed on exploratory use cases. The findings show that Virtual Commissioning is a crucial factor to engineering of advanced, sustainable production systems as well as a cornerstone of the Digital Twin.<br
Keywords: Virtual CommissioningDigital TwinSimulationHuman-in-the-Loop

Virtual Reality Unterstützung in der Simulation von Robotersystemen - Metzner, Maximilian (Digitaler Zwilling und digitaler Schatten: Von der Produktidee bis zum täglichen Einsatz, 2019)

Virtual training and commissioning of industrial bin picking systems using synthetic sensor data and simulation (IMS 2019) - Metzner, Maximilian; Albrecht, Felix; Fiegert, Michael; Bauer, Bastian; Martin, Susanne; Karlidag, Engin; Blank, Andreas; Franke, Jörg (International Journal of Computer Integrated Manufacturing, 2021)
Defined handling of unsorted parts, known as bin picking, is a challenge in robotic automation. Available solution concepts for this problem are usually either costly or require considerable setup and tuning efforts. In this contribution, a setup for virtual commissioning of such automation systems is introduced. Using a physics-based simulation environment, a virtual stereo-camera simulation and robot controller integration, a full simulation of the bin picking cycle is possible. The setup is also used to generate realistic synthetic training data for learning-based computer vision routines. The functionality of the system is demonstrated for generating training data capable of enabling a real-life deployment of the pipeline. A simulation of both model-based and learning-based bin picking systems is also conducted. This simulation also involves the path planning and execution as well as the grasp itself, allowing for a full simulation of the bin picking cycle.
CRIS-Team WoS Importer:2021-12-17

Virtual validation of the manual assembly of a power electronic unit via motion capturing connected with a simulation tool using a human model - Bönig, Jochen; Fischer, Christian; Brossog, Matthias; Bittner, Martin; Fuchs, Markus; Weckend, Holger; Franke, Jörg (Smart product engineering, Proceedings of the 23rd CIRP Design Conference, 2013)
A key challenge for gaining important time and cost potentials in production engineering projects is an early virtual validation during the pre-series. Under the premise to replace physical by digital mock-ups, we will present requirements and solutions of a virtual validation focused on manual assembly of power electronics in automotive industry. Using a digital human model for dynamic analysis is not very prevalent, because of the high modeling complexity in the digital environment. The resulting motions of the human model are furthermore unrealistic. Hence the need for research is a time saving and, regardless, a realistic movement design for virtual validation by a human model. To achieve this goal, we use an experimental setup including a variable eight camera motion capture system, a data glove and an interface for the connection to the digital validation softwar
Keywords: human model; Motion Capture System; Simulation; virtual validation

Vision-based adjusting of a digital model to real-world conditions for wire insertion tasks - Hefner, Florian; Schmidbauer, Simon; Franke, Jörg (Procedia CIRP, 2020)
In small and medium-sized enterprises, the wiring of control cabinets is a very time-consuming process as it is mostly performed manually. Thus, a novel automated approach for wiring control cabinets with batch size 1 is provided. The task is executed by a lightweight robot and based on an ECAD model of a wired cabinet. Therefore, a method is described to export digital data from ECAD and adjust the digital information to real-world conditions. To detect the approximate real-world poses of the components, a 2D image from a stationary visual sensor is used for CAD-based template matching by normalized cross-correlation. A high accurate visual 3D sensor that is mounted on the robot end-effector is moved to the approximate poses of the component ports to measure the exact poses. The results prove the functionality of the developed method, which allows to position the robotic end-effector based on ECAD data, which is the prerequisite to measure the component port with high accuracy using the 3D sensor.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Automated control cabinet wiring; ECAD; Flexible manufacturing; OpenCV; Robot-based automation; Template matching

Vision oder Wirklichkeit: Digitale Zwillinge in der Kunststoffindustrie - Sitz, Sarah; Lechler, Tobias; Reinhard, Maximilian; Franke, Jörg (Plastverarbeiter : neue Technologien, Kosteneffizienz, erhöhte Marktchancen, 2020)
Die digitale Transformation ist schon länger ein wichtiges Entwicklungsfeld. Die Corona-Krise zu Beginn des Jahres 2020 zeigt dies mit neuer Dramatik. Viele Unternehmen sind derzeit auf der Suche nach Lösungen, die eine Fortsetzung des Tagesgeschäfts zulassen. Wenn die Umstände keine Inbetriebnahmen oder Anlagenbegehungen vor Ort erlauben, so sind remotefähige Technologien oder digitale Maschinenzwillinge eine echte Chance. Dieser Artikel stellt die Möglichkeiten durch die Nutzung von digitalen Zwillingen vor und zeigt ausgehend von einem Best- Practice-Beispiel Potenziale für die kunststoff- und kautschukverarbeitende Industrie auf.<br

Vision oder Wirklichkeit: Digitale Zwillinge in der Kunststoff- und Kautschukindustrie - Sitz, Sarah; Lechler, Tobias; Reinhard, Maximilian; Franke, Jörg (Kgk-Kautschuk Gummi Kunststoffe, 2020)

Visualization of electrolyte filling process and influence of vacuum during filling for hard case prismatic lithium ion cells by neutron imaging to optimize the production process - Weydanz, Wolfgang J.; Reisenweber, Hagen; Gottschalk, A.; Schulz, Michael; Knoche, Thomas; Reinhart, Gunther; Masuch, Michael; Franke, Jörg; Gilles, Ralph (Journal of Power Sources, 2018)
Abstract The process of filling electrolyte into lithium ion cells is time consuming and critical to the overall battery quality. However, this process is not well understood. This is partially due to the fact, that it is hard to observe it in situ. A powerful tool for visualization of the process is neutron imaging. The filling and wetting process of the electrode stack can be clearly visualized in situ without destruction of the actual cell. The wetting of certain areas inside the electrode stack can clearly be seen when using this technique. Results showed that wetting of the electrode stack takes place in a mostly isotropic manner from the outside towards a center point of the cell at very similar speed. When the electrolyte reaches the center point, the wetting process can be considered complete. The electrode wetting is a slow but rather steady process for hard case prismatic cells. It starts with a certain speed, which is reduced over the progress of the wetting. Vacuum can assist the process and accelerate it by about a factor of two as was experimentally shown. This gives a considerable time and cost advantage for designing the production process for large-scale battery cell production.
Keywords: Lithium battery; Electrolyte; Filling process; Manufacturing; Neutron imaging

Von der Energie zur Kennzahl - Die Kennzahlentwicklungskette - Bornschlegl, Martin; Paulus, Ingrid; Bregulla, Markus (ATZ - Automobiltechnische Zeitschrift, 2013)
Durch die teilweise selbst gesetzten Energie- und Umweltziele vieler OEMs müssen die jeweiligen Verantwortlichen Einsparungen nachweisen. Dazu sind Kennzahlen unerlässlich, die veränderte Rahmenbedingungen, wie beispielsweise Stückzahlschwankungen, miteinbeziehen können. Um diese Kennzahlen verlässlich und standardisiert zu konzipieren, wurde bei Audi ein Fünf-Phasen-Modell entwickelt. Dieses Modell erleichtert es den Anwendern, aussagekräftige und vergleichbare Energiekennzahlen zu konzipieren.
Keywords: Energieplanung

Von der Industrie 4.0 zur Wohnung 4.0 – Einsatzpotenziale verteilter Systemansätze im industriellen und privaten Umfeld - Michl, Markus; Schäfer, Franziska; Bauer, Jochen; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
The paper at hand compares the challenges in pushing the 4th industrial revolution onwards to those of the progressing home automation. Based on this comparison known solutions in the industry respectively home environment are put into relation in order to determine synergies for an efficient joint advancement of both application fields.
Keywords: E|Home

(untitled) - Ramer, Christina (Handbuch Fügen, Handhaben, Montieren)
Keywords: Simulation; Vorgehensweise

Vor-und Nachteile verschiedener Ernährungsindizes. Zielstellungen für einen neuen nährstoffbasierten Ansatz. - Volkhardt, Ina; Meier, Toni; Burggraf, Christine; Bauer, Jochen; Forner, Frank; Christen, Olaf (Proceedings of the German Nutrition Society, 2017)
Keywords: Nutrition

Wärmeverteilung in elektronischen Baugruppen optimieren - Hörber, Johannes; Ranft, Florian; Müller, Martin; Franke, Jörg; Drummer, Dietmar (Elektronikpraxis - Profiline, 2011)
UnivIS-Import:2015-03-09:Pub.2011.tech.FT.FT-KT.wrmeve

Warpage of transfer-molded automotive power modules - experimental characterization, numerical simulation and optimization - Sprenger, Mario; Kramer, M.; Tolyschew, E.; Steinau, M.; Renner, D.; Ottinger, Bettina; Franke, Jörg (2023 24th International Conference on Thermal, Mechanical and Multi-Physics Simulation and Experiments in Microelectronics and Microsystems, EuroSimE 2023, 2023)
Warpage behaviour of a transfer-molded power module package has been studied experimentally and numerically throughout the assembly flow. Warpage in different assembly states ((1) bare metal-ceramic substrates, (2) substrates attached to copper leadframe, (3) transfer-molded package) has been assessed and influences of variations of substrate backside structure and epoxy mold compound type onto the warpage evaluated. The numerical modeling framework build-up has been validated within this study and does allow for rapid warpage prediction based on package geometry and manufacturing process temperatures.
CRIS-Team Scopus Importer:2023-05-19

Web-based Engineering Platform for Planning and Simulation of Industrial Plants and Workcells - Brossog, Matthias; Michl, Markus; Franke, Jörg (Proceedings of the 1st International Conference on Through-life Engineering Services, 2012)
The virtualisation of the industrial planning process fostered by the application of state-of-the-art simulation systems improves its efficiency and lowers its risk significantly. Digital factory solutions are getting more and more powerful, but are not adapted to the requirements of small- and medium-sized companies. They need hardware and software independent solutions with integrated functions for essential engineering tasks. A unique data format has to be developed for connecting several standalone software tools and establishing a global communication platform. In the light of this situation FAPS developed a web-based facility planning system focussed on assembly in order to provide the advantages of virtualized planning processes to an expanded community. This framework implies a basic concept for building up an internet-based comprehensive engineering platform.
Keywords: Simulation; Web technologies; Engineering

Web-Based Platform for Planning and Configuration of Robot-Based Automation Solutions: A Retrospective View on the Research Project ROBOTOP - Schäffer, Eike; Gönnheimer, Philipp; Kupzik, Daniel; Brossog, Matthias; Coutandin, Sven; Franke, Jörg; Fleischer, Jürgen (Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021, 2022)
Automation solutions in production represent a sensible and long-term cost-effective alternative to manual work, especially for physically strenuous or dangerous activities. However, especially for small companies, automation solutions are associated with a considerable initial complexity and a high effort in planning and implementation. The ROBOTOP project, a consortium of industrial companies and research institutes has therefore developed a flexible web platform for the simplified, modular planning and configuration of robot-based automation solutions for frequent tasks. In this paper, an overview of the project's scientific findings and the resulting platform is given. Therefore, challenges due to the scope of knowledge-based engineering configurators like the acquisition of necessary data, its description, and the graphical representation are outlined. Insights are given into the platform's functions and its technical separation into different Microservices such as Best Practice selection, configuration, simulation, AML-data-exchange and spec-sheet generator with the focus on the configuration. Finally, the user experience and potentials are highlighted.

Webbasierte Werkerinformationssysteme: Datenaufbereitung und -darstellung für die Werkerführung im Global Cross Enterprise Engineering - Fischer, Carina; Lušić, M.; Bönig, Jochen; Hornfeck, R.; Franke, Jörg (wt Werkstattstechnik - Online, 2014)
Globalization does not only affect enterprises in areas such as processing and transportation of material goods, but also with a view to the associated data flows. Distributed data generation and processing places higher demands on data fusion and local use. Especially product development data have to be made available for production planning and execution in a timely, efficient and targeted way. This paper presents an approach for use in manual assembly in the field of electromobility.
CRIS-Team Scopus Importer:2023-03-07

Web- und wissensbasierter Engineering-Konfigurator für roboterzentrierte Automatisierungslösungen - Schäffer, Eike (Friedrich-Alexander-Universität Erlangen-Nürnberg, 2021)
Der Markt für roboterzentrierte Automatisierungslösungen (RA) ist ein globaler Wachstumsmarkt. Aufgrund der hohen Kosten und Komplexität von RA bleiben häufig kleine und mittlere Unternehmen (KMU) hinter diesem Trend zurück. Gegenstand und Zielstellung der Promotion ist die Schaffung von effizienten sowie skalierbaren Engineering-Konzepten und -Lösungen für die Planung von RA auf Basis von Webtechnologien. Hierfür wurden das Konzept des Engineering-Konfigurators, eine microservicebasierte Webplattform-Referenzarchitektur sowie eine für Engineering-Konfiguratoren benötigte Entwicklungsmethode basierend auf drei Teilmethoden (W1-W3) eingeführt. Über nutzerzentrierte Entwicklungsansätze, eine modulare Architektur für RA sowie Ansätze aus der wissensbasierten Konfiguration (Teilbereich aus der künstlichen Intelligenz (KI)) werden der Vertrieb, die Planung und das Engineering von RA einem breiteren Publikum zugänglich gemacht. Validiert wurden die Konzepte und Methoden im Rahmen der Webplattform ROBOTOP sowie anhand diverser 3D-Web-, AR (Augmented Reality)- und VR (Virtual Reality)-Mehrbenutzer-Demonstratoren. Die Konzepte und Methoden befähigen somit auch eine effiziente Digitalisierung bzw. Prozessautomatisierung des Engineerings von RA durch die eingeführten, strukturierenden Methoden zur Wissenserfassung, -modellierung sowie -implementierung und unterstützen dabei die Vision des digitalen Zwillings im Kontext von Industrie 4.0. The market for robot‐centric automation (RA) solutions is a global growth industry. Nevertheless, due to the high cost and complexity of robotcentric automation solutions, small and medium‐sized enterprises (SMEs) often fall short of this trend. Subject and objective of the dissertation is the creation of efficient and scalable engineering concepts and solutions for the planning of RA solutions based on web technologies. For this purpose, the engineering configurator concept, a microservice‐based web platform reference architecture, and a development method required for engineering configurators based on three sub‐methods (W1‐W3) were introduced. Via user‐centered development approaches, a modular architecture for RA solutions as well as approaches from knowledge‐based configuration (subfield from artificial intelligence (AI)), sales, planning and engineering of robot‐centered automation solutions are made accessible to a broader audience. The concepts and methods were validated in the context of the ROBOTOP web platform as well as by means of various 3D web, AR (Augmented Reality) and VR (Virtual Reality) multi‐user demonstrators. The concepts and methods thus also enable efficient digitalization or process automation of the engineering of RA solutions through the introduced, structuring methods for knowledge acquisition, modeling as well as implementation and thereby support the vision of the digital twin in the context of Industry 4.0. <br
Keywords: Planung; webbasiert; wissensbasiert Engineering; configurator; knowledge-based; Industrieroboter; Fertigung; Anlagenplanung; Konfigurator; Expertensystem; Simultaneous Engineering; Software Engineering; Digitalisierung; Ingenieurwissenschaften; Produktionstechnik; Maschinenbau

Weiterentwicklung dielektrischer Elastomeraktoren zu Antriebselementen nachgiebiger Robotersysteme - Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg (Internationales Forum Mechatronik 2013, 2013)

Worker information systems including dynamic visualisation: A perspective for minimising the conflict of objectives between a resource-efficient use of inspection equipment and the cognitive load of the worker - Lušić, Mario; Braz, Konrad Schmutzer; Wittmann, Stephan; Fischer, Christian; Hornfeck, Rüdiger; Franke, Jörg (Advanced Materials Research, 2014)
In the context of casting mould inspection, the conventional paper-based provision of information for workers can be characterised by a conflict of objectives. On the one hand, a minimisation of the cognitive load of the worker is desirable. To this end the inspection procedure is oriented on the complete processing of each view of the single-part drawing. This leads to a necessary change between inspection devices within individual views. On the other hand, a resource-efficient use of inspection equipment is desirable. To this end, the inspection tasks are grouped so that for each group one single inspection device is assigned. This requires a change between the views of the single-part drawing within each inspection device, which increases worker’s cognitive load. By means of a realistic representation of the inspection operations to be carried out, by using a Worker Information System which is based on animated graphical representations (dynamic visualisation), the increase of the cognitive load that is caused by the resource-efficient use of inspection equipment could be compensated.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Inspection; Quality assurance; Worker information system

Worker Information Systems: State of the Art and Guideline for Selection under Consideration of Company Specific Boundary Conditions - Lusic, Mario; Fischer, Christian; Bönig, Jochen; Hornfeck, Ruediger; Franke, Jörg (Procedia CIRP, 2016)
Due to customer specific products, the number of product variants and the complexity of assembly processes increase. To meet these challenges, worker information systems are used to manage information diversity in manual assembly and to provide the right information at the right time in a lean way. Such systems are available in various types and their classification depends on a particular point of view. In order to enable a holistic overview of the existing diversity, this paper summarizes such systems and their benefits. For this purpose, available categories are shown. Accordingly, this paper serves as a summarizing report for the state of the art. Furthermore, the implementation and configuration of worker information systems depend on company specific boundary conditions. Considering them, a guideline is presented for the selection of worker information systems.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Information; Worker information system

Worker information system to support during complex and exhausting assembly of high-voltage harness - Fischer, Christian; Bönig, Jochen; Franke, Jörg; Lusic, M.; Hornfeck, R. (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
There are a lot of different kinds of electric drives and each category has a different installation position within a vehicle. A huge number of variants pose a challenge for manual assembly as the varying constellations of high-voltage (HV) cables require individual assembly steps. A worker needs information both about a vehicle and about HV components with their properties. We obtained good results for this on base of a worker information system (WIS). We can visualize parts assembly using three-dimensional (3-D) objects. The results of hazard analysis are shown in text format. But a WIS lacks in representing the physical behavior of parts within assembly. Especially HV cables move in an undetermined way when they are handled. We have an approach to simulate HV cables within assembly simulation. The material properties of HV cables during distortion are calculated in a finite element analysis (FEA). These parameters flow into an assembly simulation containing flexible parts like HV cables and a digital human model. The results of simulation runs can not only be used for assembly planning but also for worker guidance. We present an approach how to qualify simulation results for import to a WIS. In addition, possible application scenarios for such a WIS are explained.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly Technologies; Worker Information System

Workplace Analysis and Ergonomics in Engineer-to-Order Production Sites: A Study on the Workplace Design of Control Cabinet Manufacturing Enterprises - Stoidner, Micha; Bründl, Patrick; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (2023 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM), 2023)
Ergonomic measures aimed at redesigning the workplace and processes are necessary to improve safety, health, and productivity. Work-related musculoskeletal disorders are a major cause of lost productivity and sick leave among workers in the European Union, with the manufacturing sector in Germany having the second highest levels in 2020. The most affected occupational group is machine operators and assemblers. This paper aims to visualize the current state of ergonomics at manual workplaces in engineer-to-order (ETO) companies. The contribution is twofold offering an adapted guideline with criteria for workplace assessment in ETO companies as well as minimum ergonomic requirements for manual workplaces. The requirements were developed based on empirical data collected in three ETO companies, specifically in the use case of control cabinet manufacturing. The findings show that the developed guideline aids managers in purposefully identifying optimization potentials at workspaces and reducing economic losses caused by working conditions.<br
Keywords: Employee welfare; Productivity; Ergonomics; Employment; Sociology; Companies; Manuals; Control Cabinet; Engineer-to-Order; Ergonomic; Workplace Design

Work space surveillance of a robot assistance system using a ToF camera - Ramer, Christina; Franke, Jörg (Advanced Materials Research, 2014)
Aufgrund der demographischen Entwicklung in Industrienationen liegt eine wachsende Herausforderung darin, Produktionsmitarbeiter durch eine Reduzierung von Belastungen vor möglichen Gesundheitsschäden zu bewahren und eine längere Erwerbstätigkeit zu ermöglichen. Ebenso ist es erstrebenswert, die Potentiale leistungsgewandelter Personen zu nutzen, wodurch angepasste Hilfsmittel zur Erleichterung des Arbeitsalltags benötigt werden. Um bereits gesundheitlich vorgeschädigte Personen schneller wieder in ihren Beruf einzugliedern, erscheint es zudem denkbar Rehabilitationsmaßnahmen durch geeignete Roboterassistenten zu unterstützen. Diese Ziele werden bei der Entwicklung des vorgestellten Roboterassistenzsystems verfolgt. Um Menschen sicher im Arbeitsraum eines assistierenden Roboters erkennen und verfolgen zu können, werden visuelle Sensortechnologien zur 3D-Raumüberwachung benötigt. Herkömmliche Kamerasysteme, die ein 2D-Intensitätsbild ihrer Umgebung liefern, sind stark anfällig gegenüber Helligkeitsänderungen, was ein sicheres Personentracking kaum möglich macht. Ein neuerer Vertreter der indirekten Licht-Laufzeitmessung (Time-of-Flight, ToF) stellt die PMD (Photonic Mixing Device)-Technologie dar, bei der die Entfernungsinformation in jedem Pixel einer Sensormatrix in Echtzeit bestimmt werden kann. Auf Grund der Vorteile wurde für das Assistenzsystem eine ToF-Kamera ausgewählt. Im Versuchsaufbau wurde die Kamera zunächst zentral über dem überwachungsraum angebracht, um weitestgehend alle Kollisionsobjekte ohne Abschattungen detektieren zu können. Zu Beginn der Arbeitsraumüberwachung werden die vorverarbeiteten 3D-Koordinaten zusammen mit den bereitgestellten Intensitäts- und Amplitudenwerten der ersten Kameraframes zur Generierung eines Referenzbildes herangezogen. Die Detektion von Kollisionsobjekten erfolgt über die Differenzbildung zwischen initialem Hintergrund- und dem aktuellem Kamerabild. Aus den Differenzwerten wird für jedes Pixel die Wahrscheinlichkeit, ein Objekt abzubilden, berechnet und in diskrete Klassifikationsstufen eingeordnet. Sie ergibt sich im Wesentlichen aus der Höhen- und Intensitätsdifferenz des betrachteten Pixels sowie dessen acht Nachbarpixeln. Mittels eines Region-Growing-Algorithmus werden alle Nachbarn von Pixeln einer hohen Klassifikationsstufe, den sogenannten Start- oder Seedpixeln, in einem der Objektwahrscheinlichkeit angepassten Umkreis untersucht und im Falle einer hohen Objektwahrscheinlichkeit zu diesen hinzugezogen. Die Erstellung einzelner Objekte erfolgt aus zusammenhängenden Bereichen mit mindestens vier Bildpunkten. Um erkannte Objekte wiedererkennen zu können, werden diese mit einer Reihe ermittelter Attribute gespeichert. über eine Hochrechnung der aktuellen Position wird zunächst nach bekannten und in einem weiteren Schritt nach neuen Objekten gesucht. Die Wiedererkennung bereits detektierter Kollisionsobjekte erfolgt bei der überschreitung eines in Versuchen ermittelten übereinstimmungswerts, der sich aus mehreren Vergleichs-kriterien zusammensetzt. Eine automatisierte Bahnplanung ermöglicht den Einsatz auch bei veränderten Umgebungsbedingungen des Assistenzsystems, ohne auf geschultes Personal zum Teachen des Roboters zurückgreifen zu müssen. Um die für die zeitkritische Kollisionsvermeidung und die Pfadfindung notwendigen Abstandsberechnungen zu be-schleunigen, werden die detektieren Kollisionsobjekte mittels einfacher Hüllkörper, sogenannter Bounding Volumes, approximiert. Eingesetzt werden orientierte Hüllquader (Oriented Bounding Boxes), Hüllzylinder und kugeln sowie sogenannte -kapseln (Zylinder mit Halbkugelenden). Basierend auf einer sensorischen überwachung des Roboterarbeitsraums in Echtzeit und der dynamischen Anpassung des Umgebungsmodells kann somit die Basis geschaffen werden, um einen kollaborierenden Betrieb zwischen zu unterstützenden Werkern und dem Roboterassistenten zu ermöglichen.
Keywords: Arbeitsraumüberwachung; Roboterassistenzsystem; ToF-Kamera; PMD-Kamera; 3D-Kamera; Objekterkennung; B|Mech

Zukunft im Blickpunkt - Kreis, Oliver; Christoph, Frank Ralph (Unicum Beruf Magazin, 1999)