Numerical Simulation of the Laser Welding Process for Electrical Steel Laminations - Ziegler, Marco; Brandl, Florian; Franke, Jörg; Kühl, Alexander (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
Soft magnetic cores in electric machines conduct and enhance the magnetic flux. The magnetic properties of the single sheets are mainly influenced by the alloying elements, the microstructure and the rolling and annealing process. To reduce eddy current losses during operation, soft magnetic cores are laminated. However, all manufacturing processes and the further assembling steps, like mounting of the stator, change the magnetic properties of the stack. Laser welding is a common method for producing lamination stacks, as very thin sheets can be welded automatically with high velocities. However, the weld seams are electrically conductive connections, which lead to an increase in eddy current losses. Furthermore, the microstructure in the heat-affected zone is impaired, which leads to a higher demand for magnetization and increased hysteresis losses. A main reason for this is the magneto-mechanical effect, as mechanical stresses influence the magnetic properties. For improvement, the process parameters must be adapted to the specific material system and the requirements. In this paper, a numerical simulation model for visualizing and optimizing the heat distribution in welded electrical steel laminations is presented. The main objective is the analysis of the weld dimension for different welding parameters. For this purpose, a transient thermal analysis is carried out with Ansys Workbench. The welding process is mapped in a simplified way with a moving heat source for different conditions. To validate the results, a comparison to experimental tests is applied. In this way, the simulation results are verified and potential sources of errors are identified.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electrical steel; Finite element analysis; Joining processes; Magnetic losses; Soft magnetic materials

Numerische Untersuchung eines Reibungsventilators - Einfluss des Nabenverhältnisses auf den Druckaufbau - Praß, Julian; Franke, Jörg (Tagungsband zum 1. E|Home-Symposium 2016, 2016)

NutriScale - Key Figures for Daily Food Choices - Bauer, Jochen; Volkhardt, Ina; Michl, Markus; Blumthaler, Christina; Wiebe, Sergej; Rashid, Ria; Franke, Jörg (Advanced Engineering Forum, 2016)

NutriScale - Key Figures for Food Selection - Bauer, Jochen; Michl, Markus; Blumthaler, Christina; Wiebe, Sergej; Rashid, Ria; Franke, Jörg (Proceedings of the German Nutrition Society – Volume 21 (2016), 2016)

Obstacle Segmentation with Encoder-Decoder Architectures in Low Structured Environments for the Navigation of Visually Impaired People - Seßner, Julian; Schade, Fabian; Franke, Jörg (Proceedings of the Annual International Conference of the IEEE Engineering in Medicine and Biology Society, EMBS, 2022)
Orientation and mobility of visually impaired people usually requires intensive training with mobility aids (e.g. white canes). Assistance systems capture information from the environment, process sensor data and provide the results to the impaired user. The paper presents an approach for efficient segmentation of obstacles in low-structured outdoor environments using encoder-decoder deep learning architectures and depth images. Therefore, an efficient method for generating training data using the v-disparity method is presented. Based on an extensive dataset of RGB and depth images and the corresponding binary label images, different state-of-the-art encoder-decoder architectures are evaluated on a mobile computing unit with respect to accuracy and efficiency. Besides pure depth-based architectures, RGB-D fused architectures are evaluated, too. The quantitative results show some limitations, but an additional qualitative evaluation proves the applicability of the approach to support the navigation of VIP by mapping the position of surrounding obstacles. Thus, an efficient combination of classical image processing, the integration of knowledge about the physical nature of the environment and deep learning can be made. Clinical Relevance- The approach supports the navigation of visually impaired people, which enables a more self-sufficient life related to higher quality of life.
CRIS-Team Scopus Importer:2022-10-14

Occurrence and Influence of Fretting Corrosion on Receptacle Contact Resistance - Friedlein, Matthias; Gräf, Daniel; Jaumann, Andreas; Raiser, Fabian; Franke, Jörg (2018 IEEE Holm Conference on Electrical Contacts, 2018)
Over the years, a complex spectrum of reliability testing was set up for electrical components. Necessary, but time- and cost-intensive qualification tests delay the development of new wiring harness components. Consequently, the acceleration of lifetime tests is of crucial importance for identifying and preventing damage mechanisms even before usage. Increased temperatures and relative movements both influence the tendency for fretting corrosion, which is the most relevant damage mechanism in receptacle contacts. This paper designs and constructs a test-setup that aims at introducing damage mechanisms in contacts. To replicate damage occurring during thermal shock testing, thermal and mechanical influences are separated by inducing relative movement between the electrical contacts. Fretting amplitudes taken from literature as well as simulations serve as a basis for the tested micro-movements. To investigate the occurring damage, laser scanning microscopy, an EDX spectrum and analysis of resistance progressions are carried out. The results show a clear correlation between the damage and the induced relative movements. Therefore, the presented test-setup provides realistic test-conditions for investigating degradation mechanisms of receptacle contacts. Further investigations provide the possibility of accelerating qualification investigations by higher fretting frequencies. <br
Keywords: automotive; contact resistance; degradation mechanisms; fretting corosion; reliability; thermal-shock testing; wire harness

On modelling and simulation of dielectric elastomer actuators via electrostatic-elastodynamic coupling - Schlögl, Tristan; Leyendecker, Sigrid; Reitelshöfer, Sebastian; Landgraf, Maximilian; Yoo, In Seong; Franke, Jörg (Proceedings of the IMSD, 2014)
The aim of this work is to set up a numerical framework to characterise the deformation process and effective forces when voltage is applied to dielectric elastomer actuators (DEA). As with capacitors, when an external voltage is applied to the conductive layers, an electric field is established. Resulting Maxwell stresses lead to a contraction of the DEA. These effects are described by the Maxwell equations, the balance of momentum and constitutive material laws. Based on a model for non-linear electro-elasticity that covers the static case only, inertia terms are included in order to obtain a description of the deformation process depending on time. A potential energy function that is composed of Neo-Hooke material behaviour, electric field energy and coupling terms covers the material behaviour. Combined with the kinetic energy, a Lagrange function forms the basis in a variational setting of the model. Approximating the action integral using quadrature rules, discretising with finite elements in space and finite differences in time and applying a discrete version of Hamilton’s principle [9], a structure preserving integration scheme for DEAs is obtained and evaluated
UnivIS-Import:2015-04-16:Pub.2014.tech.FT.ltd.onmode

On molecular statics simulations of ferroelectric functional materials - Steinmann, Paul; Endres, Florian (Proceedings in Applied Mathematics and Mechanics, 2015)
The simulation of ferroelectric materials on the atomistic length scale is getting more and more important due to recent advancements in related manufacturing technologies. Therefore, we present an extended molecular statics algorithm in order to not only compute equilibrium configurations efficiently but also to consider the deformation of a discrete particle system due to macroscopic stress. Furthermore, we discuss the impact of mechanical stress and strain on the spontaneous polarization and the magnitude of the coercive field of a ferroelectric barium titanate system.

On the quality and the accuracy of the laser direct structuring, experimental investigation and optimization - Bachy, Bassim; Süß-Wolf, Robert; Franke, Jörg (Journal of Laser Applications, 2018)
The enormous applications of the molded interconnect devices (MID) make these face many difficult challenges, some of which are the quality and the reliability, as well as concerns on how to produce the micro-MID products. This drives to a hard competition between the different methods used in the MID technology. The laser direct structuring (LDS) has clearly been distinguished as the best method in comparison with the other MID processes. However, it also needs more development, especially in terms of the quality, accuracy, and their impact on the final MID quality of the two- (2D) and three-dimensional (3D) micro and normal products, especially with the decline or the limited availability of information in both of the industry and scientific research. In this work, the MID-LDS has been experimentally investigated by considering the effect of the important process parameters on the process responses and then to explore the relationship between these responses and the final MID quality and reliability. These experimental works were based on the design of the experimental tool, which employed a full factorial design for the LDS process parameters. They include the laser power, structuring speed, laser frequency, hatching percentage, the incident angle, and the focal length. The experiments have been performed on the polymer plates of Poly Ether Ether Ketone (PEEK) materials. During the experiments, different measurements have been implemented to find out the correlation between the adopted parameters and the 3D surface roughness, structuring percentage, structuring type, and ablation type, which are regarded as the most important features of LDS quality. Further measurements focus on the LDS accuracy and the final quality and reliability of the metallization structure, which includes the metallization thickness, the surface roughness, and the adhesion strength. The analysis of these experimental results showed that the quality and reliability, especially the adhesion strength and the surface roughness, of the final MID products are deeply related to the structuring percentage, structuring type, ablation type, and finally, the surface roughness.
CRIS-Team Scopus Importer:2023-03-07
Keywords: laser direct structuring; LDS accuracy; LDS quality; MID reliability; molded interconnect devices

Ontology-based Description of Energy Optimization Potentials for Production Environments - Brandmeier, Markus Andreas; Schäfer, Franziska; Kreitlein, Sven; Franke, Jörg (Energy Effiency in Strategy of Sustainable Production, 2015)

Ontology-based user guidance for energy efficiency optimization measures - Brandmeier, Markus Andreas; Franke, Jörg (Proceedings of the 6th International Conference on Industrial Engineering and Operations Management, 2016)
Energy efficiency has grown to a critical competitive factor of production systems. Governmental and non-governmental organizations as well as commercial consultants provide solutions for energy management. However, these institutions only draw up standards and guidelines to increase efficiency and do not provide actual measures. Due to inconsistencies in the understanding of energy efficiency, solutions are hardly comparable. Moreover, enterprises focus on knowledge about cost-efficient production systems, whereas knowledge about energy efficiency is put in second place, as the objective of environmental sustainability commonly is induced extrinsically. This leads to inefficiencies in the selection and application of energy efficiency measures. In this paper we provide an approach for using ontologies for selecting energy efficiency optimization measures. Through the use of ontologies, a categorization of energy efficiency measures is facilitated. In addition, ontologies are capable to describe relations between the concepts of the knowledge base and thus allow reasoning. Hence, the given approach is able to guide a non-expert user through the process of energy efficiency measure selection and moreover provides benchmark data for eligible solutions. Within this paper, we illustrate the application of the approach based on the examples of electric drives and pump systems.
Keywords: Energy Efficiency; Optimization; Information Retrieval; Ontology; Green Production; Knowledge Base; User Guidance

Ontology-driven data input for optimization - Brandmeier, Markus Andreas; Schäfer, Franziska; Franke, Jörg (49th Annual Simulation Symposium, ANSS 2016, Part of the 2016 Spring Simulation Multi-Conference, SpringSim 2016, 2016)
A major challenge when optimizing production facilities, whether in planning processes or with running facilities, is to describe the machines' initial state and to identify relevant optimization parameters. These factors have crucial influences on the optimization results. For conducting a simulation, relevant input data, representing starting conditions and influencing factors, have to be identified and acquired likewise. However, with growing complexity of systems, data collection is increasingly demanding and time-consuming. This task necessitates both knowledge about the process and the targets of improvement as well as a profound understanding of the system to be optimized. Actually, experts mostly have a thorough knowledge about either the optimization methodology or the production system. This leads to inefficiency when setting up the optimization or simulation base. In this paper, we present the approach of ontology-driven data collection for optimization tasks. Using a meta-ontology of a production facility, the user is guided through the process of data gathering. Depending on the improvement task, the ontology provides relevant parameters that have to be inquired. Thereby we provide a methodology to identify the entirety of input data for the simulation. The process is also applicable to facilities being planned. Thus the knowledge base can be used to support improvement tasks within the digital factory.
Keywords: Data acquisition; Meta-ontology; User interaction

Operation-oriented One-piece-flow Manufacturing: Autonomous and Smart Systems as Enabler for a Full-meshed Production Network - Scholz, Michael; Kolb, Saskia; Kästle, Christopher; Franke, Jörg (49th CIRP Conference on Manufacturing Systems, CIRP-CMS 2016, 2016)
Due to the effects of mass-customization there is an increase of the variance of products combined with a reduction of the number of units per variation. Therefore, it is necessary that the next generations of production lines, especially the assembling devices, have to be designed more adaptable. Regarding business information systems this trend is realized by an increasing digital integration of the particular units. Especially, for mass production the so called "line concept" is well established. This inflexibility of the physical material flow blocks the spread of mass-customization into established industrial sectors where linked manufacturing steps are commonly used. In a flow-orientated value stream with physically linked production units it is not possible to produce individualized products without additional expenses. Therefore, it is necessary to resolve the physically linked material flow equal to the digital integration of the units. This will lead to a physically and digitally full-meshed production site. The enabler is an autonomous navigating and smart transport system for a physical integration of the production units. Especially for the production of goods with a high variant diversity the benefits of a physically meshed production site are obviously. Each part gets his own and individual routing, which depends on the current machine availability and the setting of each machine. Furthermore, this approach creates a new degree of freedom for production site planning. The placement of the machines has not to be flow-oriented due to the individual and flexible connection by autonomous and self-navigating transport entities. Thereby, the advantages of a flow-oriented mass-production can be combined with those of a job-shop production.
Keywords: autonomous tranport system; manufacturing concept; operation-oriented one-piece-flow

Optical simulations of printed Polymer Optical Waveguides (POWs): search for their optical limitations caused by fabrication and application geometry - Backhaus, Carsten; Vögl, Christian; Zeitler, Jochen Tobias; Reitberger, Thomas; Lindlein, Norbert; Franke, Jörg (2019 Conference on Lasers and Electro-Optics Europe and European Quantum Electronics Conference, 2019)
Keywords: Polymer waveguides; Polymethyl methacrylate; Refractive index; Roughness; Surfaces; Systems design

Optimierung der Anlagen- und Prozessparameter für die zuverlässige Auslegung kupferbasierter sequenzieller Chip-Verbindungen in der Leistungselektronik - Kästle, Christopher; Blank, Thomas; Sedlmair, Josef; Weber, Marc; Franke, Jörg (Jahrbuch Mikroverbindungstechnik 2016/ 2017, 2016)

Optimierung der Anlagen- und Prozessparameter für die zuverlässige Fertigung kupferbasierter sequentieller Chip-Verbindungen in der Leistungselektronik - Kästle, Christopher; Blank, Thomas; Sedlmair, Josef; Weber, Marc; Franke, Jörg (Elektronische Baugruppen und Leiterplatten - EBL, 2016)

Optimierung der Datenvisualisierung von AAL-Serviceplattformen durch Usability-Tests - Bauer, Jochen; Kettschau, Anna-Katharina; Franke, Jörg (Wohnen - Pflege - Teilhabe - Besser leben durch Technik, 2014)
Keywords: AAL; E|Home; Mensch-Maschine-Interaktion; Smart Home

Optimierung der Industrieroboter-Geschicklichkeit durch Zwei-Arm-Kinematik, PMD Sensorüberwachung und aufgabenorientierte Programmierung für die flexibel automatisierte Komplettmontage von Elektromotoren - Buschhaus, Arnd; Franke, Jörg; Dobroschke, Andreas (2011)
Keywords: 3D-Kameras; B|Mech; electric drive; Roboter

Optimierung der Produktion durch rechnergestützte Simulation von Anlagen und Prozessen - Feldmann, Klaus; Schmuck, Tobias; Brossog, Matthias (Management am Puls der Zeit - Strategien, Konzepte und Methoden, 2007)
Keywords: Simulation; Optimierung; Produktion

Optimization approach of wireless power transfer systems for electric vehicles from a process and material perspective - Risch, Florian; Kraner, Sebastian; Schneider, Michael; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
Modern Wireless Power Transfer (WPT) systems for electric vehicles (EVs) have already shown their potential for high-power transfer efficiency in many prototypes and trials. However, WPT for EVs is a particularly demanding application and still in its early commercialization phase. There are still some barriers to overcome for a successful and large-scale implementation of WPT systems to become a preferred method for recharging EVs. For practical application in an EV, power pads need to meet strict automotive requirements (ISO/TS 16949:2009 certification). A thorough material and process analysis must be used to identify and assess failure modes and effects preventatively. In this context, it is the objective of this paper to present an automated test bench approach to precisely evaluate WPT systems with a focus on the process and material perspective.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric vehicles; process and material parameters; test bench concept; wireless power transfer systems

Optimization of Ag-Ag Direct Bonding for Wafer-Level Power Electronics Packaging via Design of Experiments - Yu, Zechun; Wang, Shize; Letz, Sebastian; Bayer, Christoph Friedrich; Häußler, Felix; Schletz, Andreas; SUGANUMA, Katsuaki (2019 International Conference on Electronics Packaging (ICEP), 2019)
In this study, Ag stress migration bonding (SMB) is demonstrated with various Ag film materials and bonding conditions. The main effects and interactions of various processing parameters such as bonding temperature, process time and applied pressure on the interfacial shear strength of the DUTs are firstly investigated via the design of experiments (DoE) method. The hillock and grain growth process in Ag films deposited on a Si substrate depending on process temperature and time has been investigated. Hillock formation is clearly observed on all film surfaces at 300 °C. Furthermore, various direct bonding tests are carried out with the optimal parameters using two different metal-stacks, Cr/Ni/Ag and Ti/Ag. Compared to the Cr/Ni/Ag metallized samples, a highly increased shear strength of 73 MPa is achieved with Ti/Ag film. In addition, the lifetime of direct bonded Ag joints was examined by passive thermal cycling tests. The results show no significant change in the shear strength after 700 thermal cycle

Optimization of a servo motor manufacturing value stream by use of 'Industrie 4.0' - Abersfelder, Sandra; Heyder, Andreas; Franke, Jörg (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
'Industrie 4.0' establishes multidirectional ways of cross-linking in the production area. Therefore, a complex integration of horizontal and vertical interactions has to work hand in hand. A closer look into present production shows a huge amount of optimization potentials on the way to a 'Smart Factory' with high product variability. Hence, one of the next milestones for production is to create a virtual image of the real products in the manufacturing execution system (MES) in order to have a gapless traceability and an extensive storage of process data along the whole value chain. Especially data mining will gain importance to scan information for meaningful correlations or creating configuration rules as well as decisions for subsequent process steps. For a servo motor production the implementation of a magnetic field measurement of rotors is an opportunity to gather data for data mining. In addition to that, other interesting benefits are expected in failure detection, quality improvement and an increase in performance. To evaluate the different mentioned areas of activity, a pilot test series is planned. It will also provide data sets for a first data mining investigation. The concept of the first rotor measurement test procedure is presented in the following.
CRIS-Team Scopus Importer:2023-03-07
Keywords: 'Industrie 4.0'; Magnetization; Servo Motors

Optimization of direct winding processes based on a holistic control approach - Lomakin, Alexander; Mayr, Andreas; Graichen, Knut; Franke, Jörg (Electric Drives Production Conference (E-DPC), 2020)

Optimization of the Process Reliability of the Ultrasonic Crimping Process by Evaluating the Mounting Conditions for Tubular Cable Lugs - Seefried, Johannes; Gläßel, Tobias; Rezler, Raphael; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production IV, 2018)

Optimization of the Ultrasonic Crimping Process of High-Frequency Litz Wires by Using Process Data Monitoring - Seefried, Johannes; Schwarz, Elisabeth B.; Bleier, Fabian; Franke, Jörg; Bergmann, Jean Pierre; Kühl, Alexander (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
From a technological point of view, the contacting process of insulated wires to contact elements is one of the most complex steps in electromechanical engineering. To establish an electrical and mechanical connection of winding ends and contact elements, commonly the wire is stripped before the actual contacting process. However, for high-frequency litz wires, consisting of up to several thousand insulated single wires, the stripping process cannot be carried out in advance. Therefore, processes such as hot crimping or ultrasonic crimping, in which the insulation is thermally removed during the crimping process, are used. The latter is characterized by a significantly lower process energy consumption compared to the hot crimping process. It is therefore most attractive for future applications, but process optimization strategies have hardly been addressed in the literature. Within the scope of this publication, several possibilities of optimizing the process of ultrasonic crimping are investigated by means of systematic process data analysis. For this analysis, directly available data from the control system like the required process energy as well as additionally acquired sensor data, such as the sonotrode oscillation, are taken into account and a variation of process control variables as well as the cable lug clamping is conducted.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Data Monitoring; Litz Wire; Ultrasonic Crimping; Ultrasonic Welding; Wireless Power Transfer

Optimization of wire harness assembly using human-robot-collaboration - Heisler, Paul; Utsch, Daniel; Kuhn, Marlene; Franke, Jörg (Procedia CIRP, 2020)
Wire harness assembly has been predominantly carried out manually so far since full automation has proved to be difficult for the manufacturing of flexible material with many variants. For productivity reasons, human-robot-collaboration (HRC) facilitates new optimization potential for manual systems by encompassing direct joint work of a human operator and a robot, combining their respective strengths at best. To identify HRC potential in wire harness assembly, we follow a cost-effective, simplistic, and easily adaptable approach by introducing an assessment system for analyzing the assembly process with respect to the capability-oriented task allocation between operator and robot. In doing so, we use multiple criteria combined with weighting factors arisen from the pairwise comparison. Necessary calculations are implemented in a Microsoft Excel file. On this basis, HRC-based application scenarios for efficient manufacturing are conceptualized, focusing mainly on pre-assembly and module-assembly. Concerning final assembly, only qualitative statements are made, as the increased complexity of these workplaces requires more extensive examination. Finally, the developed methodology and some of the scenarios are evaluated. We demonstrate that the efficiency of the widely manual production of wire harnesses can be enhanced by using HRC-enabled robots.
Created from Fastlane, Scopus look-up
Keywords: Human-robot-interaction; Wire harness assembly

Optimized Cutting Process of Flat Wires for Electric Motors with Hairpin Technology - Kühl, Alexander (2023 IEEE International Electric Machines and Drives Conference, IEMDC 2023, 2023)
In order to meet the high demand for electric traction motors in the future, it is advantageous in high-wage countries to automate the production process of electric motors as much as possible and at the same time to streamline it. One suitable technology is the hairpin-stator based electric motor. In this paper, the flexible, robot-based cutting process of hairpin windings is presented, which was developed at the Friedrich-Alexander-Univeristät Erlangen-Nürnberg (FAU). A clean and burr-free cut surface is particularly important for the subsequent joining of the wire into the stator in order to ensure a trouble-free process flow. It is also important to produce a clean cut surface, since the hairpins have to be precisely welded together at this point in order to guarantee an appropriate current flow. Within this publication, the hairpin technology and the associated process chain are first introduced and the specific requirements on the cutting geometry are explained. In the second chapter, the various cutting technologies are presented. In the following chapter, the selected cutting geometries are introduced and the development of the (robot-integrated) fixtures is described. Finally, the test execution and evaluation are shown.
CRIS-Team Scopus Importer:2023-10-06
Keywords: Cutting; Electric Motor; Hairpin; Manufacturing; Rotating Electric Machines; Transportation Applications; Winding

Optimized thin-film diffusion soldering for power-electronics production - Syed Khaja, Aarief Hussain; Kästle, Christopher; Reinhardt, Andreas; Franke, Jörg (2013 36th International Spring Seminar on Electronics Technology, ISSE 2013, 2013)
This paper gives an overview on diffusion soldering or transient liquid-phase soldering (TLPS), where the conventional electronic production processes have been optimized for being capable of producing highly durable pore-free TLPS bonds. The growth of intermetallic phases (IMP) with control of temperature and time has been investigated in production line perspective. The samples processed under optimized vacuum based vapor-phase soldering along with realization of thin solder layers down to less than 10μm are demonstrated. As a result, pore-free diffusion soldered joints filled with CuSnand CuSn phases near the chip-substrate interface have been realized. Formations of IMP with changes in optimized solder profile, solder paste, chip metallization, substrate roughness and solder paste thickness are discussed. © 2013 IEEE.

Optimizing Adhesion of Printed Conductive Lines on Additively Manufactured Ceramics - Utsch, Daniel; Häußler, Felix; Voigt, Christian; Sippel, Marcel; Franke, Jörg (46th International Spring Seminar on Electronics Technology, 2023)

Optimizing Intralogistics in an Engineer-to-Order Enterprise with Job Shop Production: A Case Study of the Control Cabinet Manufacturing - Bründl, Patrick; Stoidner, Micha; Nguyen, Huong Giang; Abrass, Ahmad; Franke, Jörg (SAE International Journal of Materials and Manufacturing, 2024)
This study underscores the benefits of refining the intralogistics process for small- to medium-sized manufacturing businesses (SMEs) in the engineer-to-order (ETO) sector, which relies heavily on manual tasks. Based on industrial visits and primary data from six SMEs, a new intralogistics concept and process was formulated. This approach enhances the value-added time of manufacturing workers while also facilitating complete digital integration as well as improving transparency and traceability. A practical application of this method in a company lead to cutting its lead time by roughly 11.3%. Additionally, improved oversight pinpointed excess inventory, resulting in advantages such as reduced capital needs and storage requirements. Anticipated future enhancements include better efficiency from more experienced warehouse staff and streamlined picking methods. Further, digital advancements hold promise for cost reductions in administrative and supportive roles.<br
Keywords: Aerospace; Automotive; Commercial Vehicle; Research and development; Production; Logistics; Traceability; Storage; Materials handling; Cutting; Optimization; Personnel; Supply chain management

Optimizing Machine Learning Performance via Dataset Generation for X-ray Image Classification - Mahr, Felix; Schmidt, Konstantin; Thielen, Nils; Sindel, Till; Franke, Jörg (2024 25th International Conference on Thermal, Mechanical and Multi-Physics Simulation and Experiments in Microelectronics and Microsystems (EuroSimE), 2024)
Automated X-ray inspection (AXI) plays a crucial role in ensuring the quality of electronic modules, especially post Surface Mount Technology (SMT) manufacturing. However, the presence of pseudo errors complicates accurate defect classification, necessitating efficient solutions like machine learning (ML) automation. This paper explores the impact of various dataset characteristics on ML model performance enhancement. Leveraging 2D grayscale X-ray images classified into “OK” (pseudo errors) and “not OK” (real errors), this methodology employs statistical tests to detect data drift over time. The hypothesis is that ML models trained on datasets with temporal and grayscale similarities exhibit superior performance. A dataset generation pipeline is proposed, integrating quality validation, grayscale segmentation, and temporal cropping, aiming to enhance model performance. While these optimized datasets demonstrate enhanced performance, they require frequent retraining due to reduced generalization. To address this, advocacy is made for a retraining pipeline and the recommendation is to utilize statistical tests for detecting data drift, enabling timely model retraining. These investigations reveal that datasets optimized for temporal and grayscale congruence significantly enhance classification accuracy. Additionally, the study demonstrates improvements in performance metrics: accuracy (99.03% to 99.63%), precision (98.59% to 99.75%), recall (97.21% to 99.33%), and F1-score (97.9% to 99.54%). The study highlights the importance of dataset optimization for improving the reliability of ML-based AXI-reclassification and suggests practical strategies for maintaining model efficiency over time X.<br
Keywords: Micromechanical devices; Measurement; Pipelines; Surface mount technology; Machine learning; Gray-scale; Microelectronics

Optimizing the wiring sequence based on a Constraint Satisfaction Problem for robot-based manufacturing of solderless wrapped connections - Hefner, Florian; Schmidbauer, Simon; Franke, Jörg (Procedia CIRP, 2022)
The manufacturing of solderless wrapped connections in traceable and reproducible high quality requires an automated manufacturing process. However, one key challenge for robot-based wiring is the definition of wiring sequence, as the proximity of the array-oriented wrapposts exacerbates tool accessibility. In this research, we optimize the wiring sequence by treating it as a constraint satisfaction problem, whereby a solution is indispensable, even if the constraints are not fulfilled. Experiments on a pilot plant for robot-based manufacturing of wrapped connections show that the percentage of automatically wired connections can be significantly increased with the developed approach.
CRIS-Team Scopus Importer:2022-12-09
Keywords: automation; Constraint Satisfaction Problem; control cabinet; lightweight robot; solderless wrapped connection; sorting algorithm; wiring

Pandemic Robot A concept for robot-based surveillance of inhabitants in elderly and nursing homes during pandemic situations - Bauer, Jochen; Dengler, Simon; Faubel, Leoni; Franke, Jörg; Ristok, Bruno; Struck, Matthias; Frischholz, Robert; Wittenberg, Thomas (Current Directions in Biomedical Engineering, 2021)
Robot-based service platforms are currently establishing themselves as new and affordable variants for supporting care in elderly, retirement and nursing homes. Many are open multifunctional platforms, which can potentially be integrated into such environments, if the necessary infrastructure is available. Furthermore, many services can be realized on these platforms, which can be used to foster distant interactions between inhabitants and care-providers, while simultaneously keeping up the quality of life of the inhabitants. Open mobile robotic platforms allow the extension with adequate new sensors. To detect infectious diseases of residents and healthcare-professionals, optical sensors can be used for the assessment of vital data such as heartrate and heartrate variability, respiratory rate, SpO2 or temperature. Additionally, you can consider demographic data (age, gender, constitution) of the observed person for the optical assessment, i.e. obtained by facial image analysis. As these mobile platforms are also equipped for telepresence, in case of detecting an infected person, these systems support video conferencing with their built-in cameras and microphones. Finally, the interaction with the electronic care record is necessary to upload all acquired vital data and further relevant information. All the named technologies have been under investigation in the past years and are currently moving from laboratory settings to real-world scenarios. Nevertheless, the smooth integration of all components into one system architecture in combination with (AI-based) data analysis are still open issues.
Created from Fastlane, Scopus look-up
Keywords: AAL; Care; Robotics; Smart Living

Parameter study on the influence of a radial groove design on the drag torque of wet clutch discs in comparison with analytical models - Neupert, Thomas; Benke, Elisabeth; Bartel, Dirk (Tribology International, 2017)
A considerable part of the power loss in disengaged wet clutches is caused by viscous shearing of the cooling oil between the clutch discs. Reducing this drag loss as far as possible is the objective of current research. This contribution deals with the measurement and analytical computation of the drag torque of a clutch disc with radial grooving. Operating parameters and diverse geometrical parameters such as groove width, depth, angle, or number are varied. A newly developed single-disc test rig by which the dependencies of the drag torque are able to be examined is used for measuring. Conclusions to the cause of the fluid flow behaviour are drawn and the results are compared to analytical calculation models.
Keywords: Clutch disc; Friction measurement; Fluid mechanics; Analytical model

Parametric study on relevant design and material parameters for reliable hard encapsulation of automotive power modules - Sprenger, Mario; Noll, Niklas; Hecht, Christoph; De Greiff, Malte; Müller, Lars; Franke, Jörg (Proceedings of the 24th Electronics Packaging Technology Conference, EPTC 2022, 2022)
In power module packaging, the standard approach for encapsulation is potting by soft silicone gels with low vis-cosity and youngs modulus. Within the last decade, hard encapsulation realized by large area transfer-molding of epoxy mold compounds has established itself as an alternative due to potential cost reduction and reliability enhancement. Large-area potting of liquid hard encapsulant material is another option for realization of a hard encapsulation. Regardless of the used process technology the large substrate, heatsink and module size in general, multi-material stack-up, heavy cyclic thermal loads during operation, high temperature and high voltage operation possess challenges to the material choice for hard encapsulation. Delamination and brittle fracture of the encapsulant and damage of the encapsulated structure through the encapsulant are the main concerns within the material selection process. Thermo-mechanical simulations can support and provide guidance within this material selection process. Therefore comparative parametric simulations have been performed within this study in order to estimate the influences of geometric parameters, such as substrate metallization thickness and heatsink thickness, and process parameters, such as curing temperature of the potting material, onto the thermo-mechanical behavior of the encapsulated packages. The concept of calculating an 'effective package coefficient of thermal expansion' is introduced in this study as a tool for effective selection of encapsulants. The obtained results can be used as a guideline for the selection of encapsulation materials for different module stack ups.
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Keywords: Encapsulation; Heating systems; Young's modulus; Thermal expansion; Thermomechanical processes; Multichip modules; Materials reliability

Path Detection with Artificial Neural Networks for the Navigation of Visually Impaired Jogger - Seßner, Julian; Lauer-Schmaltz, Martin; Reitelshöfer, Sebastian; Franke, Jörg (Dritte Transdisziplinäre Konferenz "Technische Unterstützungssysteme, die die Menschen wirklich wollen", 2018)

Path Segmentation with Artificial Neural Networks in Low Structured Environments for the Navigation of Visually Impaired People - Seßner, Julian; Schmid, Mira; Lauer-Schmalz, Martin; Franke, Jörg (Proceedings of the IEEE RAS and EMBS International Conference on Biomedical Robotics and Biomechatronics, 2020)
The number of visually impaired people is constantly increasing. Mobility aids such as white canes are designed to help these people navigate in their everyday life. However, these systems have limitations in certain environments or activities. To meet this challenge, we propose an assistance system to support the navigation of visually impaired people in low structured environments. The system captures information from its environment with a stereo camera. The disparity and color images are processed by an embedded computer which calculates a safe walking direction and accordingly provides vibrotactile feedback to the visually impaired person. This paper presents an approach to segment the traversable path in the captured color image of low structured environments using artificial neural networks. Therefore, a dataset is generated and several encoder-decoder architectures are evaluated and optimized to achieve a sufficient accuracy and real-time framerate of the binary segmentation on a mobile computer. The optimized architecture manages to segment the path with a test Intersection over Union value of 0.9378 and a segmentation time of 96 ms per image in various low structured environments.
CRIS-Team Scopus Importer:2020-11-13

Pinch Valve Approach for a Biofilm Resistant Mechatronic Intraurethral Artificial Urinary Sphincter* - Preis, Alexander; Grigull, Ronja-Celine; Wang, Yacheng; Benke, Elisabeth; Martin, Sina; Rieker, Ralf; Franke, Jörg; Reitelshöfer, Sebastian (2023 45th Annual International Conference of the IEEE Engineering in Medicine & Biology Society (EMBC), 2023)
Stress urinary incontinence is the involuntary leakage of urine during increased abdominal pressure, such as coughing, sneezing, laughing, or exercising. It can have a significant negative impact on a person's quality of life and can result in decreased physical activity and social isolation. The presented closure mechanism for a mechatronic intraurethral artificial urinary sphincter is designed to be inserted minimally invasive into the urethra. The device consists of a solid shell, which serves as a housing for the electronics and is designed to enable fixation in the urethra. During micturition, the urine flows through the system, where it is guided through an elastic silicone-tube that, on the one hand, enables closure by a squeezing mechanism and, on the other hand, prevents biofilm growth by oscillation at a frequency of 22.5 Hz. The squeezing mechanism consists of a pinch valve system actuated by a piezo motor. The system has been tested under urodynamic conditions and the results show that it is able to close the urethra effectively to restore continence. The device is able to withstand sudden loads and shows good performance in terms of biofilm prevention during first experiments with artificial urine. The results show that the mechatronic intraurethral artificial urinary sphincter has the potential to be an effective and minimally invasive alternative to current treatment options for stress urinary incontinence.Clinical Relevance— This novel concept of a mechatronic intraurethral artificial urinary sphincter presents a promising alternative treatment option for patients suffering from stress urinary incontinence. As it is designed to be inserted minimally invasive, it reduces the impact and complications associated with current treatment options. The future development and testing of the device could lead to a safe and effective option for clinicians to offer their patients with stress urinary incontinence, which can improve their quality of life, and decrease costs for society and healthcare systems.<br

Planning and Control of Robot-Assisted Process Cells for Structuring and Metallization of 3D-MID - Buschhaus, Arnd; Franke, Jörg (10th International Congress Molded Interconnect Devices, 2012)
Keywords: B|Mech

Planning and simulation of high-voltage energy storage assembly for automotive industry - from scalable product concepts via assembly planning and material flow simulation through to web-based assembly information - Bönig, Jochen; Fischer, Christian; Brandmeier, Markus Andreas; Mersdorf, Thorsten; Braun, Thomas; Mrugalla, Claudia (2013)
Electric mobility technologies are part of the future concept to reduce the emissions of greenhouse gases and thus to counteract the global warming. Although the idea of using electricity as drive energy came up in the 19 century, a considerable potential of development still remains. The automotive industry is in the midst of a time of transition, in which business may change fundamentally in order to meet the upcoming conditions. The current major challenge of e-mobility is the high-voltage battery, modern vehicle concepts focusing on. A technology that offers a high potential is the lithium ion technology. One main problem is the missing expertise in production of battery systems including the new requirements, e.g. working safety and high diversity of variants. The purpose of this paper is to analyse the production process of these storage systems regarding both concepts for managing variability for the overall production process as well as an in-depth planning of assembly. The paper scrutinizes the challenges arising from the manufacturing of storage systems on the basis of a purpose-designed demonstrator battery. In this regard the production planning process is represented by creating a virtual assembly line. Against this background different scenarios are built in order to examine the impact of various battery forms with their variety of influencing factors. Furthermore, the impact of the future's demand for high-voltage batteries on the capacity of the assembly line is to be scrutinized. For this purpose a simulation considering the influence of demand fluctuations on cycle times and buffers is built up and conducted. Eventually, the paper outlines a way of reusing the created data for an assembly information system. © (2013) Trans Tech Publications, Switzerland.
Keywords: Assembly information system; Modular design; Simulation

Planning, evaluation and comparison of electric drive systems using various configurations to increase energy efficiency and optimize alternating current drive systems - Javied, Tallal; Menk, Jochen; Franke, Jörg (ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE), 2015)
The industrial sector is the largest consumer of produced electric energy worldwide. Electric motor systems account for about 70 percent of the total industrial electricity demand and possess a great cost and energy saving potential. The paper provides an overview of global and regional efforts to create awareness for potential cost drivers in the industry. Various software and excel-based tools for a preliminary estimation of the energy consumption of electric motor systems are available in the market, but a holistic approach is missing. Therefore a framework and a systematic process for the estimation of potential energy savings in motor systems running on alternating current are illustrated in this paper. Moreover a new software tool is discussed, that allows a holistic view on all motor systems within a company without cost-intensive measurements or the use of external consultants.
CRIS-Team Scopus Importer:2023-03-07

Planung von Energieverbräuchen in der Produktion: Vorschlag und Diskussion von Methoden zur Unterstützung des Energiemanagements - Rackow, Tobias; Donhauser, Toni; Hübler, Jakob; Schuderer, Peter; Franke, Jörg (wt Werkstattstechnik - Online, 2015)
Energy management systems support the process of continuous improvement of energy consumption. In the ongoing cycle of analysis, planning and control, especially the planning of future energy consumption is torn between two alternatives that either involve a considerable amount of effort or provide little informational value. The following article introduces various approaches of planning energy consumption and evaluates them in terms of practicability.

Plasma-assisted additive apply of electric conductive structures for heating applications in the home environment - Braun, Thomas; Bürner, Johannes (Tagungsband zum 2. Green Factory Bavaria Kolloquium 2015, 2015)
Keywords: additiver Auftrag; E|Home; Leiterbahn

Platform-based service composition for manufacturing: A conceptualization - Fuchs, Jonathan; Oks, Sascha Julian; Franke, Jörg (Procedia CIRP, 2019)
With the implementation of cyber-physical production systems, a multitude of isolated industrial services utilizing versatile hardware and software components in heterogeneous and rigid system architectures are an obstacle for the consequent extension of holistic automation within production networks. To address this issue, we conceptualize a platform-based system architecture enabling value-adding service bundles based on and extending proven architectural styles. Our proposal also aims on qualifying communication systems to work transboundary in value-adding networks. The presented architecture is applied to a use case in context of maintenance. Our findings provide an adaptive conceptualization for application-specific service composition and integratio
Keywords: IIoTS platform; service compostion

Pneumatische Sensoren - Schäffer, Eike (Handbuch Mensch-Roboter-Kollaboration, 2019)

Pose error correction of a robot end-effector using a 3D visual sensor for control cabinet wiring - Hefner, Florian; Schmidbauer, Simon; Franke, Jörg (Procedia CIRP, 2020)
The wiring of control cabinets in small and medium-sized enterprises is a mostly manually performed process and very time-consuming. Thus, an automated approach for wiring control cabinets is necessary. The proposed solution is based on an ECAD model and performed by a lightweight robot. Before the wire insertion, the tip pose of the gripped wire end and the component port pose are detected by processing 3D sensor data. The sensor is able to detect wire ends with arbitrary cross-section geometries and arbitrary component port shapes. The results prove the functionality of correcting the pose of the robot end-effector with respect to a component port using a 3D sensor.
CRIS-Team Scopus Importer:2020-10-23
Keywords: Automated control cabinet wiring; Flexible manufacturing; Pose correction; Position-based visual servoing; Robot-based automation

Possibilities of Integrated Fabrication of Insulation Systems in Electric Drives by Injection Molding of Thermosets - Rösel, Uta; Kneidl, Maximilian; Drummer, Dietmar; Franke, Jörg (Polymers, 2022)
Due to the increasing demand for electro mobility and specifically for electrified vehicles, the demand for electric drive technology is expanding significantly with changing requirements in terms of the process and the application. The electrical insulation system of the stator is an essential part of the fabrication process with a high impact on the application properties. Due to limitations—for example, in terms of suitable materials for the stator insulation—a new technology of integrated fabrication by injection molding of thermosets has been founded. In this study, two epoxy (EP) types with different fillers were investigated to prove their suitability in terms of the material properties in the fabrication process and the application. A general realization of the integrated fabrication of insulation systems in electrical engineering by injection molding was proved. Further, the differences regarding the suitability of the two materials are portrayed. It was demonstrated that mainly the filler material influences the fabrication process and the properties in the application, leading to differing suitability in terms of the EP 3162 EMG within the fabrication process and in terms of XW 6640-1 within the application properties of the thermal conductivity and the thermal linear expansion. It was further shown that the filler within the material system is required to increase the thermal conductivity needed for the application. The inclusion of the filler influences the reaction kinetics and the viscosity behavior. A fabrication of the material with fillers is however still possible.<br

Potential analysis of a cloud-based energy management system for the generation of flexibilities - Fehrle, Adrian; Teske, Franz; Dorscht, Felix; Franke, Jörg (IEEE PES Innovativ Smart Grid Technologies ISGT 2021, 2021)
The energy transition confronts utilities with major challenges due to the decentralised and volatile feed-in of renewable energies. As part of the Cloud|E research project, an intelligent cloud-based energy management system (EMS) is being developed in which flexibility options are made available to the utilities by connecting components for power generation, storage and large loads that are found in private households. The potential of this system is analysed in this paper using a simulation scenario. The individual components for generating flexibilities are considered separately. The flexibility potential is presented in the form of additional revenue opportunities on the part of the utilities. It is shown that each flexibly controlled component leads to an additional profit for the utility. By varying the framework conditions in a wide-ranging scenario analysis, the robustness of the system is proven. The results demonstrate the possibility of flexibility generation in the area of electromobility. In total, the potential of a decentralised cloud-based EMS to support the utilities in times of the energy transition can be confirme
Keywords: utility; energy management system (EMS); heat pump (HP); electric vehicle (EV); photovoltaic (PV); battery storage unit (BSU)

Potential Analysis of the Use of Electric Storage Heaters for Demand Side Management Applications - Bürner, Johannes; Braun, Thomas; Gaus, Michael; Michl, Markus; Franke, Jörg (Proceedings of the 4th International Conference on Smart Energy Grid Engineering (SEGE), 2016)

Potentiale und Herausforderungen des Einsatzes von Ontologien im Smart Home - Schäfer, Franziska (Tagungsband zum 2. Green Factory Bavaria Kolloquium 2015: Energieeffiziente Produktion, 2015)

Potentiale und Risiken künstlicher Intelligenz in der militärischen Ausbildung und Anwendung - Oks, Sascha Julian; Fuchs, Jonathan; Mosig, Tim (Symposium Ausbildung Luftwaffe, 2022)

Potentiale und Risiken künstlicher Intelligenz in der militärischen Ausbildung und Anwendung - Oks, Sascha Julian; Fuchs, Jonathan; Mosig, Tim (Digitale (Aus-) Bildung: Wird Intelligenz tatsächlich „künstlich“?, 2022)
Im Rahmen der voranschreitenden Digitalisierung wird dem technologischen Konzept der künstlichen Intelligenz (KI) eine hohe Relevanz beigemessen. In Verbindung mit weiteren Technologien, wie Big Data-Analysen und Cloud-Anwendungen, bestehen Nutzungsszenarien in unterschiedlichen Domänen. Diese umfassen neben Industrie 4.0, vernetzter Mobilität, dem digitalisierten Gesundheitssystem etc. auch das (Aus-)Bildungswesen und Militär. Welche wichtige Rolle KI damit für die Bundeswehr einnehmen wird, zeigt sich exemplarisch am Future Combat Air System, das ab ca. 2040 den Eurofighter ablösen soll. Für das sich in einem deutschfranzösisch-spanischen Entwicklungsprogramm befindliche Mehrzweckkampfflugzeug stellt KI eine Kernkomponente dar, ohne die die Operation und strategische Nutzung des Plattformsystems unmöglich wäre. Ähnliche Entwicklungen finden in den anderen Teilstreitkräften und Organisationsbereichen der Bundeswehr, insbesondere dem Cyber- und Informationsraum, statt. Der sichere Umgang mit und ein umfassendes Verständnis von KI werden daher für viele Soldaten und Soldatinnen eine essentielle Kernkompetenz. Um dieses Wissen nachhaltig zu vermitteln, findet KI zukünftig auch in kompetenzbasierten Lehr-/Lernformaten vermehrt Anwendung. Der vorliegende Beitrag mit der Methode eines systematischen Literatur-Reviews analysiert diese Entwicklung kritisch aus technologischer, organisationaler und didaktischer Perspektive. Neben einer Kategorisierung von KI-basierten (Aus-)Bildungsverfahren wird dabei besonderes Augenmerk daraufgelegt, inwieweit sich KI-Algorithmen, die in Ausbildung und Material zum Einsatz kommen sollen aber mitunter im Ausland entwickelt wurden, mit den Grundsätzen der inneren Führung, dem Leitbild des Staatsbürgers in Uniform sowie den Prämissen deutscher Sicherheitspolitik in Einklang bringen lassen. Als Ausblick wird das Konzept „künstlicher Ethik“ formuliert, das dem Einsatz von KI einen regulierenden Rahmen setzt.<br

Potentials for Energy Saving and Quality Improvement of Assembly Presses Using Data Mining - Sand, Christian; Seidl, Matthias; Leinauer, Christian; Neuner, Maximilian; Meiners, Moritz; Baumann, Stephanie; Franke, Jörg (Applied Mechanics and Materials (Volume 856), 2016)

Potentials for Error Detection and Process Visualization in Assembly Lines Using a Parallel Coordinates Plot - Sand, Christian; Lechler, Tobias; Schuh, Patricia; Franke, Jörg (Applied Mechanics and Materials - Energy Efficiency in Strategy of Sustainable Production IV, 2018)
Assembly lines consist of chained or unchained stations, yet usually only single stations are regarded individually for process and quality analytics. Since the quality of the final product depends on interactions of process parameters along the assembly flow, it is insufficient to analyze process parameters of each station separately. Therefore, data of every single assembly station along the assembly line has to be collected and stored. To explore such a big amount of multidimensional data and their correlations, different techniques are established. In this paper, assembly flows and their respective data are visualized using a parallel coordinates plot (PCP). Here, this technique visualizes process parameter combinations along the whole assembly chain. The contribution of this paper is to prove that the presented approach enables a fast detection of stations with malicious impacts on the product quality, when it comes to complex assembly lines. The goal is to help users to detect global problems in those lines, not only single station problems. Furthermore, the relevance of various processes to the quality (good or defective) of the final good shall be revealed.
Keywords: Clustering; Error Detection; Assembly Lines; Parallel Coordinates; Data Mining

Potentials for Error Detection and Quality Improvement in Assembly Lines Using FFT, Clustering and Dynamic Envelope Curve - Sand, Christian; Kawan, Stephanie; Lechler, Tobias; Neher, Manuel; Schweigert, Daniel; Franke, Jörg (Applied Mechanics and Materials - Energy Efficiency in Strategy of Sustainable Production III, 2017)
Conventional serial and workshop productions use specific parameter ranges to evaluate the quality of a process. Our research showed that parameters within tolerances do not ensure good quality of the final product due to malicious parameter combinations along the assembly line. Therefore, data sets from assembly processes like force-way or force-time curves and quality measurements are evaluated in this novel approach. Using Fourier Transform, k-means, decision trees and a dynamic envelope curve, classification and process monitoring are processed in time and frequency domain. This enables new possibilities to characterize quality and process data, for advanced error detection as well as a more simplified tracing of faults. Here, holistic optimization and monitoring follows two strategies. First, a simplified tracing approach of malicious impacts regards quality results from test benches. Therefore, assembly processes are monitored and characterized by quality data. Second, defective influences, like tool break or calibration errors, are linked to variations of the usual process behavior. Here, the error detection approach focuses on process data from single assembly stations. This approach uses three different methods. First, Fourier Transform extracts additional information from process, energy and quality data. Second, k-means algorithm is used to cluster quality data and extend the data base. Third, a decision tree classifies the quality of the final good and characterizes assembly processes. Last, results of k-means clustering and selected classification methods are compared. This combination allows to increase process quality, improve product quality and reduce failure costs.<br
Keywords: Fourier Transform; Clustering; Data Mining; Dynamic Envelope Curve

Potentials of an Explicit Finite Element Analysis of the Bending Processes for Coated Copper Wires - Weigelt, Michael; Riedel, Andreas; Masuch, Michael; Mahr, Alexander; Gläßel, Tobias; Franke, Jörg (2017 7th International Electric Drives Production Conference (E|DPC), 2017)
The advancing electrification in industry and everyday life requires powerful electric drives providing highest efficiency. The winding as the core of these drives is subject to continuous development. Furthermore, it is of decisive importance to accelerate sample production for prototype construction and small series production of electric drives to shorten the innovation cycles. Coated bar-wound winding elements are increasingly important for the application in electric drives. The process window for damage free bending processes of coated copper wires is yet not defined. Structural mechanical finite element (FE) modelling is therefore a powerful tool to reduce costly trial-and-error loops and shortening development cycles for those production techniques as it provides reliable quantitative results. The aim of this paper is to propose the basics for defining a process window for the bending of flat wires using experimental bending test setups and FE-simulation tool
Keywords: finite element method; bending; flat wire

Potentials of few-shot learning for quality monitoring in laser welding of hairpin windings - Raffin, Tim; Mayr, Andreas; Baader, Marcel; Laube, Nadine; Kühl, Alexander; Franke, Jörg (Procedia CIRP, 2023)
For the analysis of high-dimensional data in electromechanical manufacturing, data-driven techniques such as deep learning show great potential. However, the vast amount of required data poses a major barrier to the industrial adoption of said techniques. In the production of electric traction drives, this situation is further exacerbated by short innovation cycles. One of these innovations is hairpin technology, which is increasingly being employed by automotive manufacturers and suppliers. In contrast to classical deep learning approaches, few-shot learning aims at generalizing well despite limited data availability. This makes it ideal for the ramp-up phase of new production technologies for which no large legacy datasets exist yet. Therefore, this paper presents an empirical evaluation of few-shot learning techniques in the context of hairpin stator production. In doing so, we evaluate and benchmark several few-shot learning architectures and traditional approaches for quality monitoring of laser-welded hairpin windings based on image data.<br
Keywords: Few-Shot Learning; Deep Learning; Hairpin Technology; Electric Motor Production; Quality Monitoring; Vision Transformer

Potentials of machine learning in electric drives production using the example of contacting processes and selective magnet assembly - Mayr, Andreas; Meyer, Alexander Wilhelm; Seefried, Johannes; Weigelt, Michael; Lutz, Benjamin; Sultani, Darius; Hampl, Marcel; Franke, Jörg (2017 7th International Electric Drives Production Conference (EDPC), 2017)
Machine learning (ML) is a key technology in data driven industries. In general, ML algorithms offer insight in complex processes by analyzing measured data without acquiring in-depth domain knowledge. In contrast to common physical simulations they do not require excessive computational time and are well suited for real time analysis. This study focuses on transferring the potential of ML to the production of electric drives. Three major issues are identified: the preprocessing of the data, dealing with small data sets and the selection of an appropriate machine learning algorithm. Depending on the specific application in production, different algorithms, for example support vector machines, neural networks, random forests or boosted algorithms come into consideration. The potential of ML in electric drives production is demonstrated using two concrete applications: In the case of contacting technologies, such as thermo and ultrasonic crimping, ML algorithms for predictive maintenance, quality management and process control are considered. The second use case covers the selective magnet assembly. Here, a ML-based concept is proposed that predicts the cogging torque by analyzing magnet properties, as well as process parameters.<br
Keywords: machine learning; electric drives; magnet assembly; contacting technologies

Potentials of Optical Coherence Tomography for Process Monitoring in Laser Welding of Hairpin Windings - Baader, Marcel; Mayr, Andreas; Raffin, Tim; Selzam, Jan Harald; Kühl, Alexander; Franke, Jörg (11th International Electric Drives Production Conference (EDPC), 2021)
Optical coherence tomography (OCT) is increasingly being used to monitor and control laser-based welding processes. With the ability to provide pre-, in-, and post-process data, OCT represents a holistic sensor solution for advanced process monitoring and seam tracking. A prospective field of application is the laser welding of rectangular copper wires for so-called hairpin stators as used in electric traction motors. For each stator, a large number of high-quality contact points must be welded in a short cycle time. The quality of a weld not only depends on the laser welding process itself but also on possible manufacturing deviations from upstream process steps. Although OCT seems promising for pre-, in-, and post-process monitoring, no scientific studies exist to date concerning hairpin welding. Starting from a profound presentation of the necessary basics, this paper outlines the potentials of OCT in laser welding of hairpin windings based on first experiments. Regarding pre-process monitoring, it is shown which deviations can be detected by OCT even before the process. Analogously, the post-process monitoring feature can be used to evaluate the resulting weld shape. Further experiments explore whether in-process OCT data can be used to determine the keyhole depth during welding, providing an estimate of the welding depth. The welding of hairpins requires complex beamlines and high focus speeds, which pose high challenges to existing OCT systems. Therefore, the proof is first provided for a simplified welding task before it is performed for the hairpin use case. From the findings gained, the need for action for future research activities is derived, primarily focusing on enabling the OCT -based in-process monitoring for the hairpin welding.<br
Keywords: laser welding; optical coherence tomography; process monitoring; hairpin technology; electric motor production

Potentials of Process Monitoring During Laser Welding of Electrical Steel Laminations - Ziegler, Marco; Mayr, Andreas; Seefried, Johannes; Kühl, Alexander; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Potentials of the Rotary Cutting Process for Electrical Steel Strip - Ziegler, Marco; Schneider, Michael; Hubert, Markus; Franke, Jörg (2018 8th International Electric Drives Production Conference, EDPC 2018 - Proceedings, 2018)
To minimize eddy current losses, stators and rotors are traditionally designed laminated. For this purpose, the single sheets are electrically separated from each other by an insulation layer. The production of electrical steel laminations for rotor and stator stacks is divided into the steps of cutting, stacking and joining. Currently, there are several possibilities for each process step. The selection of the suitable process depends on the application, quantity and size of the electrical steel laminations. In mass production, the electrical steel strip is separated mainly by stamping. In prototype manufacturing and for small series, the lamination is cut out by laser. In addition, wire EDM and water-jet cutting are applied in specific applications. Rotary cutting of electrical steel strip is a process that is not yet used in industry. However, the novel approach has a great potential, since investment and tooling costs are relatively low. Furthermore, the process is suitable for the production of thin laminations (smaller than 0.3 mm) which are used in traction motors for electric vehicles.
CRIS-Team Scopus Importer:2019-05-21
Keywords: Electrical Steel Processing; Laser Cutting; Rotary Cutting; Stamping

Potenziale zur Produktionsautomatisierung. Systematische Vorgehensweise zur Identifikation von Automatisierungsprojekten - Herbert, Meike; Selmaier, Andreas; Hefner, Florian; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Unternehmen der produzierenden Industrie, insbesondere der deutsche Mittelstand, sind bei der digitalen Transformation mit vielen Herausforderungen konfrontiert, beginnend mit der Analyse und Identifikation geeigneter Automatisierungsprojekte. In dem Beitrag wird eine ganzheitliche Vorgehensweise vorgestellt, um Potenziale für eine Automatisierung in Produktion und Logistik zu erkennen und konkrete Projekte zu definieren.<br
Keywords: Automatisierung; Industrie 4.0; Strategie

Power Cycle Testing at Low Temperature Swings – Evaluating the Stability of SAC- and SnSb-based Chip Solder Layers - Schmidt, Ralf; Kaesbauer, Michael; Sippel, Marcel; Dreher, Patrick (Proceedings of the 11th International Conference on Integrated Power Electronics Systems (CIPS 2020), 2020)

Power Cycling Lifetime of Shunt Resistors in IGBT Modules - Schmidt, Ralf; Kaesbauer, Michael; Endres, Michael; Sippel, Marcel; Botazzoli, Pietro (Proceedings of the 12th International Conference on Integrated Power Electronics Systems (CIPS 2022), 2022)

Power Forecast of Photovoltaic Systems-An Approach for Improving Energy Management of DC-Supplied Production Plants - Gutwald, Benjamin; Barth, Martin; Mönius, Oliver; Zeilmann, B.; Franke, Jörg (Congress of the German Academic Association for Production Technology, 2024)
Regeneratively fed Direct Current (DC) grids play a key role in the energy transition. The promising supply architecture for industrial plants is not only materially efficient in its topology, but it also distributes energy without large conversion losses, especially for electric drives. While the architecture already offers a particularly efficient integration for renewable energies, the natural fluctuation must be mastered in energy management. Depending on the orientation, dimensioning and geographical conditions, this paper describes an approach and implementation of power forecasting for photovoltaic (PV) systems based on numerical weather predictions. Furthermore, the associated energy management scenarios for storage and loads in DC-supplied production plants are presented. The advantages of energy forecasting lie in the optimal design of the DC-Grid components, the improvement of peak shaving and the early energy optimisation of production control through connection to a Manufacturing Execution System (MES).
CRIS-Team Scopus Importer:2023-12-15
Keywords: energy management; energy optimised manufacturing execution system; photovoltaic forecast for grid serving operation

Practices and Trends of Evaluating Software Prices in Procurement - An Empirical Study - Bodendorf, Frank; Franke, Jörg (Conference Proceedings, 2019)
Procurement decisions are particularly affected by the digital transformation in many industries. Purchasing, whose position shifts from pure procurement to value creation, has to deal more and more with digital components. These digital components, by their nature and economic characteristics, differ from conventional ones and therefore rise the cost analysis of purchasing to new challenges. Many companies are having great difficulties, especially with software, in verifying the procurement costs of such components. Evaluation of software prices becomes a more and more important part of cost engineering in companies. In theory and scientific literature, a distinction is made in software evaluation procedures between cost-, value- and license-oriented approaches. This paper presents the design and results of an empirical study to find out which of these approaches are currently being pursued and which ones are eyed for the future by companies in different industries. <br
Keywords: software procurement; value analysis; cost engineering; empirical study

Prediction of electric motor performance by in-line testing of permanent excited rotors - Abersfelder, Sandra; Meyer, Alexander Wilhelm; Heyder, Andreas; Thanner, Marius; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
The market growth of electric drives is pushed forward due to high coercive magnet material and new, more efficient motor designs. These new designs require only small tolerances within the whole manufacturing process. While quality assurance is well established within the stator manufacturing process, the rotor assembly process suffers from lack of testing. Hence, this gap causes rejects not detected until the end-of-line-test of the whole motor, measuring especially the back electromotive force (BEMF) and the total harmonic distortion (THD) of the output signal. To avoid rejects of whole motors at the end of the value chain, this paper presents the possibilities delivered by in-line magnetic field measuring of the rotor. Therefore, different testing methods, such as a commercial available monolithic hall array and a discrete hall line array are used and evaluated. Out of these measurement series a rotor KPI is defined in order to evaluate the rotor quality right after the measurement.
CRIS-Team Scopus Importer:2023-03-07
Keywords: BEMF; hall measurement; manufacturing tollerances; permanent magnet; synchronous motor

Prediction of surface roughness of laser selective metallization of ceramics by multiple linear regression and artificial neural networks approaches - Wang, Li; Silva, Lisbeth; Süß-Wolf, Robert; Franke, Jörg (Journal of Laser Applications, 2020)
Laser selective metallization of ceramics (LMC) has been widely applied to prepare high-quality electrical patterns on ceramic circuit carriers. As the dominating factor, surface roughness after laser treatment is controlled mostly by the laser technical parameters, such as laser power, scanning velocity, and laser frequency. Therefore, establishing an accurate relation between the surface roughness and the laser parameters will be of great benefit to the LMC specimens. In the present research, machine learning is used to simulate the LMC process on an alumina-copper oxide ceramic. The effect of each laser parameter and the interaction between them are revealed by the multiple linear regression method. The artificial neural network model trained with the Levenberg-Marquardt function provides the best estimation of the surface roughness after laser treatment compared with the Bayesian-regularization function and the scaled-conjugate-gradient function. The result can be used as a practical prediction and reasonable guideline for the optimization of LMC processes.
CRIS-Team WoS Importer:2020-11-27

Prediction of the Joint Cross-Section of Laser-Welded Hairpin Windings Based on 2D Image Data Using Convolutional Neural Networks - Mayr, Andreas; Hauck, Luka; Meiners, Moritz; Franke, Jörg (10th International Electric Drives Production Conference (EDPC), 2020)
Due to the increasing electrification, the demand for high-quality, cost-effective electric motors continues to rise. The hairpin winding is one such optimization, improving the slot fill factor of the motor while simultaneously facilitating handling operations in production. Since this winding technology is accompanied by a high number of joints, special attention is paid to the contacting process, with laser welding being a promising choice. Due to the many influencing and disturbing factors, the current challenge is to better monitor the welding process and to stabilize the resulting quality. Up to now, quality characteristics such as the joint cross-section can only be measured with a costly computer tomograph or destructive random testing using microsections. Therefore, this paper proposes a novel, cost-effective approach to predicting the cross-section of laser-welded joints based on 2D image data in combination with deep learning techniques. In order to investigate what kind of images are most expressive, image data are acquired at different times from different perspectives. On the one hand, pre-process images are taken to predict whether the actual position and surface condition of the pins allow a sufficient weld seam. On the other hand, post-process images are analyzed to estimate the achieved cross-section and thus the joint's functionality. For the classification of the images, a pre-trained convolutional neural network is adapted using transfer learning. To reduce the error slip, pre-and post-process images are finally evaluated in combination, resulting in a recall of 100% in the present experiment. Of course, the proposed quality prediction is not only applicable to the contacting of hairpin windings but also to other laser welding applications.
Created from Fastlane, Scopus look-up
Keywords: contacting; convolutional neural network; deep learning; electric motor production; hairpin winding; laser welding; transfer learning

Prediction of the Solder Rise in Selective Wave Soldering Comparing Decision Tree and Logistic Regression - Seidel, Reinhardt; Leibold, Fabian; Thielen, Nils; Franke, Jörg (2020)

Predictive Cost Analytics of Vehicle Assemblies Based on Machine Learning in the Automotive Industry - Bodendorf, Frank; Merbele, Stefan; Franke, Jörg (Proceedings of the 2019 Pre-ICIS SIGDSA Symposium, 2019)
Due to the high pace of development in the automotive industry there is a need for innovating cost engineering. A methodology for intelligent cost estimation in the early stages of the product life cycle is introduced. In a first step it is shown how significant economic and technical parameters for cost prediction can be prepared and filtered from historical calculation data. Subsequently, it is shown how cost prediction models can be developed using machine learning algorithms. Learning data and practical use cases come from a large automotive manufacturer in Germany. The models predict costs of car parts and assemblies of increasing complexity. Seven different machine learning models are trained and optimized. Based on the test data of the use cases these models are assessed and compared. Finally, the prediction results obtained are evaluated from different perspectives, demonstrating the practical applicability of the most suitable methods explored.<br
Keywords: Cost Engineering; Machine Learning; Predictive Analytics; Comparative Study; Automotive Industry.

Pretreatment and Structuring of Spatial Circuit Carriers Based on Alumina for High Temperatures and High Frequencies - Bräuer, Philipp; Stoll, Thomas; Muckelbauer, Martin; Hensel, Alexander; Franke, Jörg (IEEE 72ND ELECTRONIC COMPONENTS AND TECHNOLOGY CONFERENCE (ECTC 2022), 2022)
CRIS-Team WoS Importer:2022-09-23

Printing polymer optical waveguides on conditioned transparent flexible foils by using the aerosol jet technology - Reitberger, Thomas; Franke, Jörg; Overmeyer, Ludger; Wolfer, Tim; Hoffmann, Gerd-Albert (Printed Memory and Circuits II, 2016)
Keywords: Additive manufacturing; Aerosol Jet Printing; Flexographic printing; Optical; Polymer; Waveguide

Print Quality Assessment by Image Processing Methods for Printed Electronics Applications - Schirmer, Julian; Roudenko, Jewgeni; Reichenberger, Marcus; Neermann, Simone; Franke, Jörg (2018 41st International Spring Seminar on Electronics Technology (ISSE), 2018)

Problemmanagement in Werker-Assistenz-Systemen - Rupp, Stephan; Müller, Rainer; Kerker, Sebastian; Faltus, Florian; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2020)
In der Fahrzeugentwicklung sind bereits erste Planstände der Serienmontageabläufe verfügbar. Sie nutzen Assistenz-Systeme, um die Montagebläufe frühzeitig zu erproben. Da während der Entwicklung mit unreifen Prozessen und kontinuierlichen Änderungen gearbeitet wird, sollten diese Systeme auch mit auftretenden Problemen umgehen können. Für diesen Zweck wurde ein Problemmeldeprozess entwickelt und in ein Assistenz-System integriert.
Keywords: Werkerassistenz; Vorserie

Process and Energy Data Acquisition on Machining Center and Individual Machine Components - Müller, Julian; Michos, Gordana; Koch, Lukas; Hermann, Maximilian; Hubert, Markus; Franke, Jörg (Applied Mechanics and Materials, 2017)
This paper describes possibilities of process and condition data acquisition on universal milling centers with Sinumerik 840D-sl control. The measurement and process data is gathered mostly with the present control system architecture of the machine tool. This internal data collection has been extended by additional sensors and an external measurement system to enable further and partially deeper analysis. This setup is also explained in this publication. The demonstrator together with the measuring system allows an investigation of the introduced components close to reality and the observation of the overall system at once. The latter is considered energetically on a comparative measurement to ascertain discrepancies in energy consumption between two different milling strategies for a pocket cycle.

Process curve analysis with machine learning on the example of screw fastening and press-in processes - Meiners, Moritz; Mayr, Andreas; Franke, Jörg (Procedia CIRP, 2021)
With the increasing degree of digitalization in manufacturing industry, advanced data analysis techniques such as machine learning (ML) are moving into focus. In several production processes like machining or welding, ML applications already show high potential for process monitoring, optimization, or control. Although screw fastening and press-in processes are frequently employed in modern assembly lines, there are only few research approaches addressing the application of ML so far. Therefore, this paper starts with an overview of conventional and first ML-based approaches to process curve monitoring. Following this, it is shown how ML can be used to detect and classify errors in screw fastening by analyzing the resulting torque curve. In addition, an assembly line consisting of several press-in processes is used to demonstrate that ML also allows the analysis of cross-process interactions by evaluating several process curves at once. In this way, defective parts can be detected and rejected at an early stage, eliminating further processing and testing steps while simultaneously reducing cost

Process design and evaluation for the automation of interphase insulation for distributed windings - Mahr, Alexander; Kneidl, Maximilian; Regler, Johannes; Franke, Jörg (Procedia Manufacturing, 2021)
In the production of electrical machines based on the pull-in technology, the stator, with a share of 35% of the total costs, is the most expensive component in the electric motor and offers a variety of automation possibilities of the process. The insertion of the phase insulation paper into the stator winding head is mostly done within manual assembly stations. This process step offers automation potential for the production of a process-safe phase insulation. The aim is to develop and qualify an automated application method. Therefore, the process is redesigned by the idea of a robot-supported application of the phase insulation with a spray system. For feasibility studies, a robot-supported spray insulation system is designed, built and subsequently integrated into a robot cell. Using several test setups, different process tests are carried out to check the application possibilities of sprayable insulation materials as phase insulation in the stator winding head. In particular, the effects of the various process parameters on the indentation strength of the new insulation materials are being investigated using laboratory tests.
Keywords: electromechanical engineering; electrical machine; interphase insulation; automation process; robot cell

Process development for laser powder bed fusion of pure copper - Stoll, Thomas; Trautnitz, Pascal; Schmiedeke, Samuel; Franke, Jörg; Travitzky, Nahum (Proceedings of SPIE, 2020)
This paper describes the development of suitable process parameters to ensure a reproducible, defect-free production of pure copper specimen via Laser Powder Bed Fusion (LPBF) also called Selective Laser Melting (SLM). Therefore, a set of experiments was developed and evaluated in a Design of Experiment (DoE) which finally provide an indication about ideal process parameters for melting pure copper powder at a wavelength of 1064 nm. For the experiments Cu-ETP with a copper purity of more than 99.90 % was processed with a laser power of up to 500 W resulting in a maximum density of 99.82 % and an electrical conductivity of 56.88 MS/m. Besides the development of optimal parameter combinations of laser power, laser speed and hatching distance, focusing the laser beam to a spot diameter of about 35 μm with a fused silica f-theta lens and thus high laser intensities of about 416 kW/mm2 resulted in best materials properties.<br
Keywords: Kupfer; Laser; LPBF

Process Development of Screen-Printed Magnetic Sheets for Electric Machines via Statistical Design of Experiments - Schmidt, Alexander; Wieprecht, Nico; Schlichting, Johannes; Denneler, Stefan; Franke, Jörg; Kühl, Alexander (Metals, 2023)
Electrical machines play a major role in achieving a more sustainable economy by driving the further electrification of industry and transportation. To enhance the electric motor productivity during production and the efficiency during operation, it is essential to maximize the material yield rate during the production of stator and rotor sheet stacks and reduce iron losses during operation. Screen-printing technology can help to achieve these goals by producing thin magnetic sheet laminations in near-net-shape geometry, resulting in minimum material waste during production. Moreover, reducing the sheet thickness decreases the eddy current losses and avoids mechanical stress during manufacturing, leading to improved motor efficiency. Additionally, screen printing facilitates the production of multi-material components and variable alloy compositions. This study aims to identify the relevant factors and printing parameters so that screen-printed magnetic sheets can achieve product specifications. A method involving the statistical design of experiments is performed in several iterations to investigate the target parameters of the print cycle time, green part weight, shape integrity and layer thickness, and to analyze the main interdependencies. The results of this study provide valuable insights into optimizing the screen-printing process for soft magnetic sheets, enabling the production of efficient electric motors while reducing material scrap.<br
Keywords: additive manufacturing; electric motor; magnetic sheets; new materials; resource efficient production; screen printing; stator core

Process-Driven Approach within the Engineering Domain by Combining Business Process Model and Notation (BPMN) with Process Engines - Schäffer, Eike; Stiehl, Volker; Schwab, Peter; Mayr, Andreas; Lierhammer, Josef; Franke, Jörg (Procedia CIRP, 2021)
Digitization within the framework of Industry 4.0 is considered the biggest and fastest driver of change in history of manufacturing industry. While the size of a company is becoming less essential, the ability to adapt quickly to changing market conditions and new technologies is more important than ever. This trend particularly applies to the companies' software landscapes, where individual sub-processes and services must be orchestrated, seamlessly integrated, and iteratively renewed according to the ever-increasing user requirements. However, inflexible, closed monolithic software applications as well as self-programmed stand-alone tools that are difficult to integrate are still predominant in the engineering domain. A complete reimplementation of existing, proprietary engineering tools and their integration into monolithic applications of large software providers is often not economically feasible, especially for small and medium-sized machinery and plant manufacturers. In this context, the so-called Process-Driven Approach (PDA) offers a sustainable and tool-neutral opportunity for process and tool orchestration, enabling an easy integration of individual software applications by consistent utilization of the separation of concerns principle. The PDA, originating from business informatics, is mainly based on the standardized and machine-executable visual modeling language Business Process Model and Notation (BPMN). Using the semantic enhancements found in version 2.0, BPMN is not just used to model the business processes but also to model and execute the integration processes between different systems. After the PDA has already been successfully applied to large-scale projects in business informatics, it is now being transferred to the engineering domain. As shown in this paper, PDA allows to orchestrate the different processes in engineering and to integrate the underlying software tools, such as e-mail or spreadsheet applications, engineering tools, or custom microservices, using standardized interfaces like REST API. In doing so, engineering processes can be made more transparent, monitored, and optimized by means of appropriate key figures. The concept is validated by a prototypical implementation of a minimum functional PDA architecture for the engineering domain.
Created from Fastlane, Scopus look-up
Keywords: architecture; BPMN; engineering; Industry 4.0; orchestration; PDA; process engine; Process-Driven Approach

Process-Factor Optimization of Small-Area Sintered Interconnects for Power Electronics Applications - Alzoubi, Khalid; Hensel, Alexander; Häußler, Felix; Ottinger, Bettina; Sippel, Marcel; Franke, Jörg (Journal of Electronic Packaging, 2023)
Power electronics is concerned with the use of electronic devices to control and transfer electric power from one form to another. Power electronics can be found in laptop chargers, electric grids, and solar inverters. Die-attach interconnections form a critical part of power electronics devices. Silver sintering has been traditionally used for die-attach interconnections because of its high melting point and ability to form very thin thicknesses. However, the processing time compared with soldering is very long. Sintered layers might contain large voids that affect the mechanical stability of the structure. Stresses caused by mechanical and environmental conditions might cause degradation and possibly early failures. This work focuses on studying the combined effect of process factors on the shear strength of small-area die-attach interconnections in silver sintering. Design of experiments (DoE) tools were used to build an experimental matrix with a 95% confidence level. The results have shown that holding time has a considerable effect on the mechanical stability of the die-attach interconnections. Intermetallic compounds formed in the sintered joints at higher holding times resulted in fewer voids. Furthermore, the treatment level of the holding time highly affects the shear strength under other factors such as temperature and pressure.<br

Processing influences of resin-based insulation materials for wireless power transfer applications - Kneidl, Maximilian; Masuch, Michael; Rieger, David; Kühl, Alexander; Franke, Jörg (2020 IEEE Conference on Electrical Insulation and Dielectric Phenomena (CEIDP), 2021)
Due to the electrification of the whole mobility sector, the demand for new insulation materials and processes is constantly increasing. Beside the electric traction drives, new technologies such as inductive charging are becoming more and more important in electric vehicles. Especially for wireless power transfer, high-frequency litz wires are used to generate the required electromagnetic field. While semi-finished products and insulation systems are continuously developing, insulation processes like potting remain unchanged. The consequence is an inappropriate insulation of the coil structure resulting in increasing eddy current losses or breakdowns of the inductance. Additionally, high mechanical and thermal loads, occurring in a typical operation environment for electric vehicles, result in accelerated aging of the insulation material. This increases the challenges in the design and manufacturing of insulation systems for inductive power transfer devices. The aim of this work is to identify and evaluate all relevant process parameters for potting high-frequency litz wires with varying primary insulation systems. To ensure the required mechanical and electrical properties, a high degree of impregnation of the litz wires is targete

Process optimization in transient liquid phase soldering (TLPS) for an efficient and economical production of high temperature power electronics - Syed Khaja, Aarief Hussain; Franke, Jörg (CIPS 2016 - 9th International Conference on Integrated Power Electronics Systems, 2019)
The fulfilment of the goals towards the miniaturisation of devices while increasing the power densities and reducing the losses, requires reliable and cost-effective solutions for the production of power electronic modules. This is associated presently with the integration of wide-bandgap (WBG) semiconductor materials and corresponding design customization. Diffusion soldering particularly Transient Liquid Phase Soldering (TLPS) which is a proven thermally stable die-attach technology has been focused in this contribution. This paper contributes on the feasibility of TLPS as a cost-effective production strategy for high-temperature silicon and WBG power electronics. This contribution also focuses on the usage of Cu-Sn preforms as die-attach material. The optimised temperature profiles by combination of reducing and inert gases for void-free TLPS interconnect are introduced. Three phase rectifier bridge modules were constructed to check the feasibility of TLPS in serial production. The variation of intermetallic phase (IMP) formations in Cu-Sn and Cu-Sn-Ni preforms on bare and Ni-plated copper substrates, thermal treatment temperature and time are discussed. For improved handling of preforms and enhanced IMP formation, cladded Cu-Sn preforms are introduced and their characteristics are investigated. The advantages of process optimisation and its potential for flexibility and mass production are discussed.
CRIS-Team Scopus Importer:2019-10-22
Keywords: Die-attach; Diffusion soldering; High temperature; Lead-free; Power modules; Preforms; Process optimisation; TLPS; Wide-bandgap

Process Reliable Laser Welding of Hairpin Windings for Automotive Traction Drives - Gläßel, Tobias; Seefried, Johannes; Masuch, Michael; Riedel, Andreas; Mayr, Andreas; Kühl, Alexander; Franke, Jörg (IEEE International Conference on Engineering, Science, and Industrial Applications (ICESI), 2019)
Keywords: Electric Drives Production; Hairpin Winding; Contacting Technologies

PRODISYS – Engineering Produktionsbasierter Dienstleistungssysteme - Bernard, Michael; Duchon, Markus; Eitner, Felix; Fuchs, Jonathan; Kipouridis, Orthodoxos; Mosig, Tim; Neubert, Colette; Oks, Sascha Julian; Rehman, Kasim; Reidt, Andreas; Stelzner, Jörg; Weiss, Steffen (2021)
Keywords: Service; Industrie 4.0

Product Design Improvement Through Knowledge Feedback of Cyber-physical Systems - Brandmeier, Markus Andreas; Bogner, Eva; Brossog, Matthias; Franke, Jörg (Proceedings of the 26th CIRP Design Conference, 2016)
In context of automation the concept of cyber-physical systems creates a consistent data interchange via open and global information networks with bidirectional flow of information. However, in order to generate potential benefits, relevant process data has to be identified and transferred to usable knowledge. In this paper we propose an approach for using the information feedback, provided through cyber-physical systems within production facilities, for the enhancement of the product design process. Due to the integration of knowledge bases, the data gathered in production is transformed to knowledge for improvement, which is structured for re-utilization with the use of ontologies.
Keywords: Cyber-physical systems; Knowledge feedback; Ontologies; Product Design

Production and Characterization of High-temperature Substrates through Selective Laser Melting (SLM) for Power Electronics - Syed Khaja, Aarief Hussain; Perez, Philip; Franke, Jörg (2016 IEEE CPMT Symposium, 2016)
Additive manufacturing (AM) is a key technology as energy, material and resource efficient alternative to conventional subtractive and formative production technologies enabling better flexibility and customization. In this contribution, powder-based additive layered manufacturing namely selective laser melting (SLM) is focused to check the potential for substrate manufacturing, system integration and packaging concepts in electronic systems particularly for high-temperature mechatronic applications. This work focuses on the process development for the generation of conductive patterns on ceramic substrates by SLM technique for copper based powder materials. The obtained layer thicknesses and the mechanical stability are discussed. The generated structures were characterized by investigating the current carrying capability and also to identify the defects and process-generated failure mechanisms. The potential of SLM for high temperature applicability is further discussed.
Keywords: Additive Manufacturing; Ceramic substrates; Current carrying capability; High temperature; Mechatronic Integrated Devices; Power electronics; Selective Laser Melting

Production Concepts for Inductive Power Transfer Systems for Vehicles - Kühl, Alexander; Kneidl, Maximilian; Seefried, Johannes; Masuch, Michael; Weigelt, Michael; Franke, Jörg (Energies, 2022)
The option of wireless energy transmission in electric vehicles can become the main market driver for electric vehicles due to its distinct advantages, such as range, weight, or costs, over conventional conductive charging solutions. In addition to the great potential, which different research work and realized systems have already shown, there are new requirements for the associated production networks in the automotive industry which must be addressed at an early stage. Furthermore, no solutions currently exist for the industrial production of these components. This paper presents the main components for the feasibility of wireless power transmission in electric vehicles. In addition, the required value chains and processes for the new components of the inductive power transfer systems, and the final assembly for induction coils, which has been developed at the FAU, will be presented. These include the developing of a winding process on a 15-axis special machine, ultrasonic crimping of the litz wire ends, and vacuum potting.<br

Production processes for wireless charging infrastructure. A large-scale market introduction of electric powered vehicles is still opposed by many barriers Produktionsprozesse für kontaktlose Ladeinfrastrukturen: Kosteneffiziente Produktion und Integration von Systemen zur kontaktlosen Übertragung von Energie in stationäre und bewegte Elektrofahrzeuge - Risch, Florian; Kühl, Alexander; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2011)

Produktionsmanagement als effizientes Werkzeug zur Vernetzung von Forschungsprojekten - Ziegler, Christian; Stockinger, Andreas; Stoll, Tobias; Wittmann, Stefan; Weickmann, Johannes; Schmidt, Jürgen; Topic, Irena; Schuck, Marcus; Cojutti, Massimo; Al-Sheyyab, Ahmad (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2007)
LFT Import::2019-07-16 (1501)

Produktionstechnologien für die Antriebe der Zukunft: Anwendungsorientierte Forschung am E|Drive-Center des Lehrstuhls FAPS in Nürnberg - Kühl, Alexander; Mayr, Andreas; Masuch, Michael (Automobiltechnologie in Bayern + e-Car, 2018)

Programming and evaluation of a multi-Axis/multi-process manufacturing system for mechatronic integrated devices - Ankenbrand, Markus; Eiche, Y.; Franke, Jörg (2019 International Conference on Electronics Packaging, ICEP 2019, 2019)
Additive manufacturing technologies open up new paths in the production of Mechatronic Integrated Devices (MID) and enable rapid and cost-efficient fabrication of demonstrators and customer-specific applications with lot size one. The MID technology is used in many applications in the automotive, medical and telecommunication industry and allows a high amount of functional integration. In this work, a 5-Axis all in one machine is used to combine Fused Filament Fabrication (FFF) for the additive manufacturing of substrates, a Piezojet print head for generating circuit tracks as well as a vacuum pipette for placing surface mounted devices (SMDs). Conductive paths can be printed with Piezojet on arbitrary freeform surfaces because of the high possible working distance. After the printing process of the part is completed, the utilized conductive silver paste is cured in a convection oven. The SMDs are placed directly into the liquid paste, which also contains adhesives. The 5-Axis motion system enables the mounting of components at any position of a hemisphere. On the software side, a CAD/CAM system is extended by a slicer, printed electronics functionality and Pick and Place operations in order to allow the generation of one single machine program for the automatic manufacturing of mechatronic products. A machine simulation is programmed to validate generated programs before executing them on the real system. All tools are mounted in the system simultaneously and are activated by tool change commands in the NC program.
CRIS-Team Scopus Importer:2019-07-12
Keywords: Additive Manufacturing; Mechatronic Integrated Devices; Printed Electronics

Proportional Control of a Soft Cable-Driven Exoskeleton via a Myoelectrical Interface Enables Force-Controlled Finger Motions - Walter, Jonas; Roßmanith, Paul; Souza de Oliveira, Daniela; Reitelshofer, Sebastian; Del Vecchio, Alessandro; Franke, Jörg (International Conference on Biomedical Robotics and Biomechatronics (BioRob), 2022)
We report new electromyography (EMG) and finger motion data that address the question of whether a proportional EMG control of a soft cable-driven exoskeleton enables force-controlled finger motions. To investigate this question, we conducted experiments with a self-built state- of-the-art cable-driven exoskeleton for a single finger and a healthy subject. The finger exoskeleton weighed only 44 g and was built from low-cost materials (ultra-high-molecular- weight polyethylene cord, DC motors, 3D-printed components). The goal of this study was to show whether the subject can remotely control a finger of their left hand (slave), to which the exoskeleton is attached, with a finger of their right hand (master) based on the EMG activity of the forearm muscles. The results show that the proportional EMG control enables force-controlled motions of the slave finger, while it was ensured that the healthy subject did not manipulate the data. Moreover, the data show that this type of control allows a modulation of the fingertip forces.<br

Prospects of wire bonding as an approach for contacting additive manufactured Aerosol Jet printed structures - Kästle, Christopher; Hörber, Johannes; Öchsner, Florian; Franke, Jörg (Proceedings of the 20th European Microelectronics Packaging Conference (EMPC), 2015)
Additive manufacturing can be a truly transformative force for manufacturing flexibility by cutting prototyping and developing time, enabling complex shapes and structures, and reducing material waste. The growing demand for 3D electronic devices and customized electronic components as well as for a high level of integration can be met by 3D Aerosol Jet printing. This versatile maskless printing-method offers a broad range of application for fine pitch structures on various substrates. In order to apply Aerosol Jet printing in complex and highly integrated devices, connections between printed structures and active components such as sensors or LEDs, as well as to the peripheral package need to be established. In this context wire bonding bears the chance as a most cost-effective and flexible interconnect technology for assembling a vast range of semiconductor packages with Aerosol Jet printed circuits.

Prototyping and Production of High-temperature Power Electronic Substrates through Additive Manufacturing Processes - Stoll, Thomas; Syed Khaja, Aarief Hussain; Franke, Jörg (Journal of Microelectronics and Electronic Packaging, 2017)
Keywords: Power electronics; Additive manufacturing

Prozessbegleitende Qualitätssicherung in der Elektronikproduktion - Wilke, Peter; Feldmann, Klaus; Götz, Knuth (Tagungsband Symposium Anwendung von Fuzzy Technologien und Neuronalen Netzen, 1996)
UnivIS-Import:2017-01-09:Pub.1996.tech.IMMD.IMMD2._proze

Prozessflexible Steuerung von Industrierobotern - Brossog, Matthias; Hartmann, Christian; Kohl, Johannes; Merhof, Jochen; Reichenbach, Marc; Fey, Dietmar; Franke, Jörg (wt Werkstattstechnik - Online, 2014)
In addition to individuality and flexibility, the PCB (Printed Circuit Boards) technology is increasingly expected to demonstrate its potential for energy efficiency. This article describes a test system with an industrial robot for the handling of electronic boards including an automatic calibration system based on optical sensors and different measurement concepts for visualization and optimization of energy consumption. The sensors were integrated into the control of the overall testing system by means of OPC UA.
UnivIS-Import:2015-03-09:Pub.2014.tech.IMMD.IMMD3.prozes
Keywords: Steuerung; Energieeffizienz; Sensorik

Prozesssimulation - Brossog, Matthias; Schäffer, Eike (Handbuch Mensch-Roboter-Kollaboration, 2019)

Pushing the Boundaries of 3D-MID: Pulse-Width Modulated Light Technology for Enhancing Surface Properties and Enabling Printed Electronics on FFF-Printed Structures - Gräf, Daniel; Neermann, Simone; Stuber, Lisa; Scheetz, Matthias; Franke, Jörg (2018 13th International Congress Molded Interconnect Devices (MID), 2018)
Keywords: aerosols; ink; light sources; mechatronics; nanoparticles; polymers; rapid prototyping (industrial); silver; sintering; surface roughness; surface treatment; three-dimensional printing; xenon; light sintering; pulse-width modulated light technology; printed electronics; fused filament fabrication; aerosol-jet printing system; 3D-MID; surface roughness; heat sensitive materials; polylactic acid; surface treatment; silver nanoparticle ink; Ag; Surface treatment; Rough surfaces; Surface roughness; Printing; Field-flow fractionation; Ink; Silver; Additive Manufacturing; Printed Electronics; Fused Filament Fabrication; Surface Treatment; Silver Nanoparticle Ink; Aerosol-Jet Printing; Pulse-Width Modulated Light Technology; Sintering Process

Qualification of channels produced by laser powder bed fusion: Analysis of cleaning methods, flow rate and melt pool monitoring data - Kolb, Tobias; Mahr, Alexander; Huber, Florian; Tremel, Jan; Schmidt, Michael (Additive Manufacturing, 2018)
Laser powder bed fusion, is an additive manufacturing technology that is used in industry for rapid prototyping and manufacturing of aftermarket products, molds and special machine parts. Quality assurance and process stability still require improvement until this technology is ready for large scale serial production. Scan strategies and parameter sets for manufacturing are often fixed when certification processes are finished. Thus, it is important to test the manufacturability of specific design features such as inner channels. In the following we will present the qualification of inner channels in different test parts for the aluminum alloy AlSi10Mg and the stainless steel 1.4542. The testing includes different cleaning methods and air flow rate measurements. Additionally, we will compare such parts and LPBF specific problems to observations with a coaxial melt pool monitoring system.
Keywords: Additive Manufacturing measurement techniques melt pool monitoring laser powder bed fusion

Qualification of dielectric elastomer actuators as artificial muscles for highly dynamical N-DOF robot kinematics - Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg; Leyendecker, Sigrid (Proceedings of the 6th International Symposium on Adaptive Motion of Animals and Machines, 2013)
UnivIS-Import:2015-04-16:Pub.2013.tech.FT.ltd.qualif

Qualification of main impacts on the inductive skinning process of copper wire bundles - Spreng, Simon; Borngraeber, Thorsten; Gläßel, Tobias; Franke, Jörg (ICEC 2016 - 28th International Conference on Electric Contacts, 2016)
Aside from the distinct contacting process, within the field of electric drives production, the quality of the isolation skinning process has to be assured. One promising technology in this context is the inductive skinning process, which utilizes skin and proximity effects occurring at high-frequency alternating currents. By the use of these physical impacts, the surface of insulated copper materials can be strongly heated up in short process times, leading to an extensive removal of the thermosetting insulation coatings. The following paper presents the results, which were experienced by using an inductive skinning machine with frequencies of 280 kHz. Here, insulated copper wire bundles serve as application example, whereby the number and size of copper wires, as well as the insulation type is varied. Subsequently, different technologies e.g. mechanical and magnetic crimping to perform the following contacting process are qualified and evaluated against each other.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electric drives manufacturing; Inductive skinning; Joining process

Qualification of NIR, UV and Laser Irradiation as Alternative Photonic Sintering Methods for Printed Electronics - Neermann, Simone; Steindl, Michael; Franke, Jörg; Mayer, Edgar; Schmidt, Michael (2020 Pan Pacific Microelectronics Symposium, 2020)
Printed Electronics creates new areas of applications with a new manner of manufacturing electronics. Due to its technical and 3D design freedom, new markets and innovative products arise that were initially unthinkable. However, the focus of research is currently on mastering and improving the printing process. The subsequent process step of drying and densifying the printed structures to achieve high conductivities in the shortest possible time is up to now hardly considered. This paper treats the inquiry of fitted and optimized parameters of alternative promising photonic sintering methods for printed electronics compared to the much more time-intensive state of the art sintering process in a furnace. These photonic sintering methods comprise the near infrared, ultraviolet light as well as laser irradiation of the printed structures. Photonic sintering promises faster and more efficient curing and sintering due to the direct and selective application of energy to the printing structures without damaging the temperature-sensitive substrates. As substrate materials ABS and PC-ABS, as well as a glass material were used. Both polymer materials are standard and technical thermoplastics which are available at the market in huge quantities at low price. For the manufacture of printed circuits, a dispense printer was used, in order to process a low-cost silver-based micro particle paste. The evaluation of the sintering result was carried out based on the electrical conductivity of the printed conductor path and the adhesion strength on the substrate. In addition, the sintering time required for the curing of the structures as well as impacts on the substrate or the printed tracks due to photonic treatment were taken into account. To perform the experiments, two different print layouts were set up in order to be able to assess the electrical properties on the first layout and the adhesion on the second layout. To obtain a detailed statement on the exploration on the photonic sintering methods, a fully factorial design plan was conducted. For the near-infrared irradiation, the important parameters were the irradiation duration and the irradiation power. While sintered by ultraviolet light, the parameters were irradiation time, as well as the distance between the sample surface and the UV emitter. In the treatment by means of laser radiation, laser power and the motion speed were identified as the relevant parameters. In order to be able to draw a comparison to the mainly used sintering method, samples were also sintered in a furnace. The results show a significant reduction of the sintering time to a few seconds with comparable and even significantly better electrical and mechanical properties.
CRIS-Team Scopus Importer:2020-05-15
Keywords: Alternative Sintering; Conductivity; Photonic Sintering; Polymer; Printed Electronics

Qualifizierung Dielektrischer-Elastomer-Aktoren zum Einsatz als künstliche Muskeln in hochdynamischen N-DOF Roboterkinematiken - Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg; Leyendecker, Sigrid (6. Bremer Bionik Kongress - Tagungsbeiträge, 2012)
UnivIS-Import:2015-04-16:Pub.2012.tech.FT.ltd.qualif

Qualifying dielectric elastomer actuators for usage in complex and compliant robot kinematics - Reitelshöfer, Sebastian; Landgraf, Maximilian; Schlögl, Tristan; Franke, Jörg; Leyendecker, Sigrid (3rd international conference on Electromechanically Active Polymer (EAP) transducers & artificial muscles (EuroEAP), 2013)

Qualifying dielectric elastomer actuators for usage in complex and compliant robot kinematics - Reitelshöfer, Sebastian; Landgraf, Maximilian; Schlögl, Tristan; Franke, Jörg; Leyendecker, Sigrid (EuroEAP, 2013)

Qualitative assessment of the impact of manufacturing-specific influences on Machine Learning Operations - Raffin, Tim; Reichenstein, Tobias; Klier, Dennis; Kühl, Alexander; Franke, Jörg (Procedia CIRP, 2022)
Machine Learning Operations (MLOps) enables the streamlining of the development and deployment processes of machine learning models; thus, manufacturers can utilize the inherent flexibility and adaptability of Deep Learning at scale to further optimize their processes. This publication provides insights into the challenges that companies face while striving for the efficient operationalization of machine learning algorithms. Moreover, a mapping of capabilities and requirements is presented to provide a baseline for the qualitative analysis of the current state of the art. In conclusion, this article discusses the shortcomings of the existing literature and provides novel implications for MLOps systems in manufacturing.<br

Quantification of the influence of varying electrode shapes and materials on the thermo-crimping process of standardized tubular cable lugs - Spreng, Simon; Gläßel, Tobias; Muselmann, Johannes; Wörrlein, Marina; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
The main joining task in the field of electric drives production is to connect bundles of insulated copper wires with standardized tubular cable lugs, as this connection alternative is widely used in all types of different electrical stator varieties. Implementing this process in industrial production facilities, the thermo-crimping technology is widely used. Within this technique, the insulation is thermally destroyed, while coincidently, the tubular cable lug and the inlying skinned copper wires are deformed plastically, which generates a force fit crimp-connection. The thermo-crimping process features strong production-related benefits such as short tact times, high process reliabilities as well as an easy process handling. The severe disadvantage however has to be seen within the electrode wearing, as the crimping tools are simultaneously exposed to high pressures and temperatures of at least 600 C reducing an electrode's number of possible crimping routines to at most 1500. As a consequence, especially in serial production, excessive maintenance efforts have to be taken into account, strongly reducing the production efficiency. For this purpose, the institute FAPS focuses its research on the reduction of tool wearing. Beginning with a theoretical process analysis, different tool shapes and materials are compared experimentally considering both, the joint quality and the electrode wearing. Subsequently, regression models are introduced predicting static quality properties such as tensile forces and transition resistances. Finally, the proposed model is validated by applying the found formula to different cable lug sizes.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric drives manufacturing; thermo crimping; varying electrode shapes

Quo vehis, Electromobility? - Weigelt, Michael; Mayr, Andreas; Böhm, Ralf; Kühl, Alexander; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2018)
The spread of electromobility is still far behind the objectives and expectations of politics and society. Up to now, the relatively high vehicle costs, politically sanctioned energy prices, the limited vehicle ranges and the inconvenient charging process represent the major barriers. At the same time, several drivers exist, such as the superior efficiency, emission-free driving, conservation of fossil resources and the impressive driving enjoyment. This article summarizes the drivers and barriers of the electromobility from an ecological, economic and social perspective. Finally, the challenges for the technology development and the production technology are derive

Quo vehis, Elektromobilität? - Weigelt, Michael; Mayr, Andreas; Böhm, Ralf; Kühl, Alexander; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2018)
Die Verbreitung der Elektromobilität in Deutschland liegt nach wie vor hinter den Zielen und Erwartungen von Politik und Gesellschaft zurück. Bisherige Hemmnisse der Mobilitätswende sind vor allem die relativ hohen Anschaffungskosten von Elektroautos, die politisch sanktionierten Strompreise, die begrenzten Reichweiten sowie der noch wenig komfortable Ladevorgang. Dem stehen wiederum zahlreiche Treiber wie der überlegene Wirkungsgrad, das emissionsfreie Fahren, die Schonung fossiler Ressourcen sowie der beeindruckende Fahrspaß gegenüber. Der vorliegende Beitrag fasst die aktuellen Treiber und Hindernisse der Mobilitätswende aus ökologischer, ökonomischer und sozialer Perspektive zusammen und leitet daraus Herausforderungen an die Technologieentwicklung und Produktionstechnik a

Räumlich und mit feiner Struktur: Die 3D-Technologie auf dem Vormarsch - Goth, Christian; Kuhn, Thomas (Kunststoffe, 2015)
Molded Interconnected Devices (MID) sind dreidimensionale elektronische Baugruppen. Ihre Stärken liegen in der hohen Gestaltungsfreiheit, dem erreichbaren Miniaturisierungsgrad und der damit einhergehenden Gewichtsreduktion sowie in der Integration einer Vielzahl von Funktionalitäten. Diese mechatronischen Systeme werden in verschiedensten Anwendungsfeldern wie Automobil, Industrieelektronik, Medizintechnik, Telekommunikation und Sensorik eingesetzt. Interessante 3D-MID (spritzgegossene Schaltungsträger)-Komponenten beleuchtet der nachfolgende Beitrag. Er zeigt die Trends der genannten Anwendungsfelder, die sich in hohem Maße auf die Entwicklung der Prozesse, der Anlagentechnik und vor allem der Werkstoffe für die 3D-MID-Technologie auswirken. Hierzu zählen der zunehmende Bedarf an feineren Leiterbahn-Strukturen, die deutlich unter dem bisherigen Standard von 150 extgreekmm liegen, die notwendige Wärmeverteilung insbesondere für LED-Applikationen, eine hohe Zuverlässigkeit trotz steigender Umweltanforderungen und kostengünstige Systemlösungen vergleichbar mit konventionellen Technologien (z. B. starre und flexible Leiterplatte). Die Werkstoffentwicklung zielt demzufolge auf die Realisierung feinerer Füllstoffpartikel, wärmeleitfähiger Materialien bzw. Systeme und die Qualifizierung alternativer Hochleistungstypen als technologisch und wirtschaftlich interessante Alternativen zu dem bewährten LCP (Liquid Crystal Polymer oder Flüssigkristallpolymer)-Typ Vectra E840i LDS der Celanese GmbH, Sulzbach. Ergänzend zu den thermoplastischen Materialen werden auch neue Entwicklungen im Bereich der spritzgießfähigen Duroplaste betrachtet.
Keywords: E|P; MID

Reachability analysis for cooperative processing with industrial robots - Wagner, Maximilian; Heß, Peter; Reitelshöfer, Sebastian; Franke, Jörg (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2017)
The cooperation of several industrial robots can improve processes or even makes new processes possible. In the scope of this work, the effect of the cooperation on the reachable workspace is investigated. Thus, the approach of reachability maps is extended to cooperative processing by simultaneously moving the tool and the workpiece. This allows a general statement about the improvement of the workpiece related reachability due to the simultaneous movement of tool and workpiece. A dual arm robot setup is used for implementation and the cooperative movement is compared to single arm movement by generating reachability maps for each case. In doing so, it is also presented how the integration of a collision detection improves the representativeness of the reachability maps.
CRIS-Team Scopus Importer:2023-03-07

Real-time image of production. Material flow simulation during operation Betriebsbegleitende materialflusssimulation echtzeitabbild der produktion - Donhauser, Toni; Endter, Udo; Schmidt, Torben; Baier, L.; Schuderer, P.; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Systems for production planning and control (PPC) can only consider time-dynamic interactions to a limited extent. This is enabled by adding simulation functions, leading to more efficient and viable plans. Appropriate interfacing of the simulation model to operational automation and data acquisition systems creates the required production-synchronous digital twin. This linking is explained in detail in this article.
CRIS-Team Scopus Importer:2020-07-31

Reasoning over OPC UA Information Models using Graph Embedding and Reinforcement Learning - Bakakeu, Jupiter; Schäfer, Franziska; Franke, Jörg; Baer, Schirin; Klos, Hans Henning; Peschke, Joern (Proceedings - 2020 3rd International Conference on Artificial Intelligence for Industries, AI4I 2020, 2020)
With the fourth industrial revolution, the OPC Unified Architecture (OPC UA) [1] has emerged as the standard communication framework for the implementation of cyber-physical production systems since it can be used for both, communication and information modeling. Even though OPC UA helps bridge the interoperability gap at the automation level, its semantic has not yet been formally defined and generated or manually created OPC UA information models are often incomplete and inconsistent making an efficient automated reasoning and knowledge inference on the OPC UA address space particularly challenging.In this paper, we show that it is possible to train a machine learning system on OPC UA information models, such that it performs automated reasoning over OPC UA knowledge graphs with high precision and recall. More specifically, we present a reinforcement learning based solution that learns to reason on semantically incomplete OPC UA information models by constructing multi-hop relational paths along an embedded vector space of the knowledge graph representing the information model. The construction of such relational paths allows the discovery of missing relations between the entities and at the same time the evaluation of the truth of the encoded triples, thus enabling consistency checks and questions answering.
CRIS-Team Scopus Importer:2021-04-19
Keywords: entity relation extraction; graph embedding; knowledge inference; link prediction; machine learning; multi-hop reasoning; OPC UA; reinforcement learning

(untitled) - Brossog, Matthias; Michl, Markus (Handbuch Fügen, Handhaben, Montieren)
Die rechnergestützte Planung von Montagezellen ist ein Teilbereich der Digitalen Fabrik, die laut VDI-Richtlinie 4499 als Gesamtheit aller Mitarbeiter, Softwarewerkzeuge und Prozesse, welche zur Erstellung der virtuellen und realen Produktion notwendig sind, definiert wird (VDI 4499). Dieser Ansatz bietet vielfältige Potenziale, die bislang vor allem in größeren Unternehmen mit eigenen Simulationsabteilungen oder von kleineren und mittleren Unternehmen (KMU) unter Beauftragung von Engineering-Dienstleistern ausgeschöpft werden. Weit verbreitet sind auch heute noch die Vorbehalte, wenn es um die Einführung dieser neuen Technologien in Unternehmen geht. Dabei werden meist die hohen Kosten im Vergleich zu einem schwer abzuschätzenden Nutzen als Hauptargument gegen den Einsatz von Methoden der Digitalen Fabrik genannt. Ebenso führen der erforderliche Einarbeitungsaufwand in Verbindung mit der Bereitstellung von qualifiziertem Personal sowie der hohe Modellierungsaufwand vor allem bei 3D-Modellen nicht selten zur Vermeidung rechnergestützter Hilfsmittel. Das immense Potenzial zur Beschleunigung der Prozesse durch Parallelisierung der Produkt- und Produktionsplanung wird bei der Abwägung oft nicht betrachtet. Ziel dieses Beitrags ist es daher, durch Aufzeigen rechnergestützter Methoden samt dazugehöriger Beispiele insbesondere auf die Vorteile eines durchgängigen Einsatzes von Werkzeugen der Digitalen Fabrik bei der Planung von Montagezellen aufmerksam zu machen. Dabei stehen einerseits technische und organisatorische Aufgaben wie die Planung des zelleninternen Materialflusses, der Teilebereitstellung sowie der Handhabung und Speicherung von Bauteilen unter Berücksichtigung der Wirtschaftlichkeit im Fokus. Andererseits wird sowohl auf die Gestaltung manueller Arbeitsplätze und der Arbeitsumgebung nach ergonomischen Gesichtspunkten als auch auf die Besonderheiten bei der rechnergestützten Planung automatisierter Montagezellen eingegangen.
Keywords: Montage; Planung; Entwurf

Recognition and Description of Unknown Everyday Objects by Using an Image Based Meta-Search Engine for Service Robots - Reitelshöfer, Sebastian; Meister, Sebastian; Franke, Jörg (Advanced Engineering Forum Vol. 19, 2016)
In future applications service robots will operate in complex and unstructured environments. While performing daily tasks such systems will have to recognize many different unknown objects in order to be able to conduct continuative processes. To support enhanced functionalities of a service robot system an image based meta-search engine that is accessible for a machine can be used. In this contribution the realization of an approach to determine reasonable identification results for single and multiple everyday objects by using the Google reverse image search system is described. In order to deliver convenient results for the communication of a robotic system with a human user the generated search results are post-processed and prepared in order to provide reasonable object descriptions. To enable an intuitive application, control a gesture based approach allows potential users to initialize a search procedure by pointing at an object of interest while being observed by a camera system. The performed experiments show a quite reliable detection behavior for a reasonably broad variety of everyday objects.
Keywords: Object Recognition; Service Robot; Meta-Search Engine; Robot Operating System (ROS)

Reducing energy consumption of industrial robots in manufacturing systems - Paryanto, Paryanto; Brossog, Matthias; Bornschlegl, Martin; Franke, Jörg (International Journal of Advanced Manufacturing Technology, 2015)
Reducing the energy consumption of industrial robots (IR) that are used in manufacturing systems has become a main focus in the development of green production systems. This is due to the reality that almost all automated manufacturing processes are using IR as the main component. Thus, reducing the energy consumption of IR will automatically reduce operating costs and CO2 emissions. Therefore, a method for reducing the energy consumption of IR in manufacturing systems is desired. Firstly, this paper presents a literature survey of the research in energy consumption analysis of IR that is used in manufacturing processes. The survey found that current research in this field is focused on the development of simulation models of IR that are able to be used to predict its energy consumption. Secondly, a modular model to analyze power consumption and dynamic behavior of IR is developed. Afterward, an experimental investigation is carried out to validate and estimate the accuracy of the model developed. The investigation shows that the developed modular model can be conveniently used to optimize the industrial robot’s operating parameters, which are commonly needed for production planning and at the process optimization stage. In addition, the investigation shows that the process constraints, environment layout, productivity requirement, as well as the robot payload and operating speed are the key factors that must be considered for optimizing the productivity and efficiency of IR.
Keywords: Energy efficiency; Industrial robots; Power consumption; Manufacturing systems; Production planning; Operating parameters

Reduzierung der Durchflußmengenstreuung laserstrahlerzeugter Bohrungen - Geiger, Manfred; Hoffmann, Peter; Bartl, Norbert; Schmidt-Hebbel, Robert (Abtragen und Bohren mit Festkörperlasern, 1993)
LFT Import::2019-07-15 (405)

Reference Architecture and Agile Development Method for a Process-Driven Web Platform based on the BPMN-Standard and Process Engines - Schäffer, Eike; Schobert, Marvin; Reichenstein, Tobias; Selmaier, Andreas; Stiehl, Volker; Herhoffer, Markus; Mala, Matûs; Franke, Jörg (CIRPe 2021 Sustainable, resilient, and agile manufacturing and service operations: Lessons from COVID-19, 2021)
One of the major trends in the 21st century is the trend towards digital transformation within Industry 4.0. In order to adapt to high volatile market conditions, especially in the context of COVID-19, companies do not only have to transfer their knowledge into digital systems. Furthermore, they have to be able to tailor their business processes rapidly to changing customer’s needs. The implementation of efficient and transparent processes is thereby known as the process of digital transformation and requires its underlying software-architecture to be highly flexible and scalable. Especially a web-based platform represents a highly user-centered application for multi-user purposes and can quickly adapt to its customer needs. While e-commerce and video-streaming platforms, like eBay or Netflix, often already provide a highly flexible, microservice-based architecture, common tools and platforms within the engineering-domain are usually still based on rather monolithic or service-oriented architectures (SOA). Therefore, an adaption to changing market conditions and the integration of proprietary tools is often technically demanding and economically not feasible, especially for small and medium-sized enterprises (SME). In this context, the so-called Process-Driven-Approach (PDA) offers a sustainable and tool-neutral blue-print for a system’s architecture strictly following the separations-of-concerns principle and allowing a user-centered layout. The PDA enables the integration of business processes and tools within an orchestrating framework, provided by a process engine. While the PDA within the engineering domain has been presented in a preceding paper, this paper supposes a reference architecture and agile development method for engineering-platforms via the PDA based on the BPMN-standard and process engines. These concepts are validated by a prototypical implementation of a platform-demonstrator for tool-supported planning of robot-based automation solutions.<br
Keywords: Process-Driven web platform; reference architecture; ROBOTOP; Process-Driven-Approach; PDA; agile; user-centered; development method

Reinforcement learning for energy reduction of conveying and handling systems - Schmidl, Elisabeth; Fischer, Eva; Steindl, Johanna; Wenk, Matthias; Franke, Jörg (Procedia CIRP, 2020)
One important reason for wasting energy in manufacturing processes is that individual plant components often consume too much energy despite not being needed for production or nothing being produced at that moment. The implementation of standby-strategies in the PLC to switch each component into an optimal energetic state is applied seldom due to the great programming effort. This is because there are many functional dependencies between the plant components and therefor the PLC program must be adapted manually to the respective manufacturing process. The presented solution shows an intelligent system, which can adapt to plant-specific process requirements and derive decisions about the optimal energetic state of each component autonomously. In this paper, we provide an approach that uses reinforcement learning algorithms, which train on virtual plant models. The results are verified on a conveying and handling system in our learning factory.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Energy reduction; Reinforcement learning; Virtual commissioning

Relation of joining parameters of stator core production and iron loss - Schneider, Michael; Urban, Nikolaus; Franke, Jörg (2017 7th International Electric Drives Production Conference, EDPC 2017 - Proceedings, 2018)
The demand for environmentally friendly and sustainable mobility leads to the increasing spread of electric vehicles. An important part of the electric drive is the stator. This is made up of many laminated steel sheets. The production quality of such a laminated stator core is effected by the essential process steps of cutting, joining and winding. The causes of potential losses can arise in each of these phases. At high frequencies, the eddy current losses dominate the iron losses and thus also the major part of the total losses. Different manufacturing technologies for joining the laminations are often compared in literature to highlight differences. Within the scope of this publication, different joining technologies are compared with respect to the hysteresis and eddy current losses influenced by them. For this purpose, differently manufactured ring core samples with multiple production parameters are examined. In particular the increase of the iron losses caused by the local and global generation of conductive paths in the sheet metal package is the focus of interest here. Subsequently, the losses resulting from baked resin and welding joining technology are determined and compared by means of measurements. We present industry relevant results by considering the specific hysteresis and eddy current losses according to DIN DIN EN 60404-6. The experiments are carried out varying different process parameters like welding seams, welding energy, feed speed and pressure, baking time and temperature with regard to diameters of ring core samples.
CRIS-Team Scopus Importer:2023-03-07
Keywords: baked varnish; iron losses; laminated core; measurement; sheet metal; welding

Reliability assessment and thermal characterization of automotive power module package based on novel thick copper-ceramic substrate and hard epoxy encapsulation - Sprenger, Mario; Forndran, Freerik; Ottinger, Bettina; Braun, Tobias; Franke, Jörg (Proceedings of the 12th International Conference on Integrated Power Electronics Systems (CIPS 2022), 2022)
Standard automotive power modules with sixpack topology and highest power density rely on metal ceramic substrates, direct liquid cooling by copper heat sinks and soft encapsulation by silicone gel. This study assesses the influence of novel thick copper substrates (TCS), with copper metallization thicknesses up to 2 mm, aluminium heat sinks and hard encapsulation by epoxy potting on the thermal performance and reliability of a power module package. Soft potted power modules based on AMB substrates soldered onto a copper heat sink are compared to soft and hard potted TCS based modules on an aluminium heat sink. Thermal impedances Zth j-f of all three mentioned module types are determined by FEM simulation and validated against impedance values measured during power cycling. TCS modules (Zth j-fFEM = 0.19) show better performance than AMB modules (Zth j-fFEM = 0.27). Resistance of the solder interconnection between substrate and heat sink against thermo-mechanical stress is assessed by thermal shock tests. All modules types are therein able to meet the requirements set for the increase in thermal resistance within ECPE Guideline AQG 324. Differences between AMB and TCS delamination characteristics and the beneficial influence of hard potting onto solder delamination are investigated by scanning acoustic microscopy (SAM). The thermal shock experiments are accompanied by thermo-mechanical simulations for additional quantification of AMB, TCS, heat sink and epoxy potting influence on the accumulation of plastic strain in the soldered substrate attach, as well as the sintered die attach layer.
Keywords: encapsulation; power electronics; hard encapsulation; thick copper substrate; thermal characterization

Reliability of 3D-Opto-MID Packages for Asymmetric Optical Bus Couplers - Lorenz, Lukas; Hanesch, Florian; Nieweglowski, Krzysztof; Hamjah, Mohd Khairulamzari; Franke, Jörg; Hoffmann, Gerd-Albert; Overmeyer, Ludger; Bock, Karlheinz (IEEE 71ST ELECTRONIC COMPONENTS AND TECHNOLOGY CONFERENCE (ECTC 2021), 2021)
CRIS-Team WoS Importer:2021-10-29

Reliability of LDS Conductor Paths - Influencing Factors and Characterization Methods - Fischer, Andreas; Müller, Hagen; Kuhn, Thomas; Drummer, Dietmar; Kück, Heinz; Franke, Jörg (11th International Congress Molded Interconnect Devices, 2014)
Keywords: 3D-MID; E|P; Elektronikproduktion; Zuverlässigkeit

Reliability of lead-free solders for die attach in automotive power modules - Ottinger, Bettina; Holverscheid, Joshua; Konig, Sebastian; Jerichow, Edgar; Lunz, Sebastian; Sprenger, Mario; Muller, Lars; Goth, Christian; Franke, Jörg (Proceedings of the 24th Electronics Packaging Technology Conference, EPTC 2022, 2022)
Four Sn- based solder joint materials SAC305, SnSb5, SnSb10 and PFDS400® were compared conducting active power cycling tests. In addition, the microstructure before and after the power cycling test was analyzed. Intermetallic compounds were detected at all tested solders after the soldering process. The composition and the amount of intermetallic compound (IMC) phases differed between the solders. The PFDS400® solder joint which consisted mostly of Cu6Sn5 intermetallic compound and an intermediate copper layer showed the highest lifetime followed by SnSb5, SnSb10 and SAC305 solder. While SAC305, SnSb5 and SnSb10 failed due to material fatigue, the PFDS400® solder joint did not show any cracks, damage, or delamination.
Created from Fastlane, Scopus look-up

Reliability of Mechatronic Integrated Devices Regarding Failure Mechanisms - Bräuer, Philipp; Wurzer, Lukas; Kuhn, Thomas; Knoeller, Andrea; Mueller, Hagen; Eberhardt, Wolfgang; Zimmermann, Andre; Franke, Jörg (2020 43RD INTERNATIONAL SPRING SEMINAR ON ELECTRONICS TECHNOLOGY (ISSE), 2020)
CRIS-Team WoS Importer:2021-02-26

Reliability of Molded Interconnect Devices regarding Crack Initiation and Overmolding - Bräuer, Philipp; Kuhn, Thomas; Müller, Martin; Franke, Jörg (2019 42ND INTERNATIONAL SPRING SEMINAR ON ELECTRONICS TECHNOLOGY (ISSE), 2019)
CRIS-Team WoS Importer:2020-01-31
Keywords: 3D MID; reliability

Reliability of Piezojet-Printed Conductive Lines on Alumina Substrates Produced by Fused Filament Fabrication - Utsch, Daniel; Häußler, Felix; Sprenger, Mario; Zirn, Julian; Franke, Jörg (2023 15th International Congress Mechatronic Integration Discourse (MID), 2023)
Increasing demand for efficiency of 3D mechatronic integrated devices (MID) typically require substrates with increased temperature resistance. Thus, in this work ceramic materials such as alumina are used instead of thermoplastics. For spatial integration and freedom of design, the ceramic substrates are printed using Fused Filament Fabrication. After chemical and thermal post-treatment, conductive lines are printed on the ceramic substrates by piezojet-printing with silver-based ink and sintered in a convection furnace. The reliability of the produced specimens is assessed by testing procedures based on IEC 60068 (temperature shock test and humidity-heat-test). In the conducted tests, the printed material compound suggests to be robust to the applied conditions. Therefore, these reliability evaluations of piezojet-printed conductive lines on additively manufactured alumina indicate a promising suitability of ceramic substrates for MID.<br
Keywords: Fabrication; Resistance; Mechatronics; Three-dimensional displays; Ink; Thermal conductivity; Ceramics; Mechatronic Integrated Devices; ceramics; Additive Manufacturing; Piezojet-printing; Reliability

Reliability of Printed Microwave Electronics - Neermann, Simone; Franke, Jörg; Sippel, Mark; Lomakin, Konstantin; Gold, Gerald (IEEE 71ST ELECTRONIC COMPONENTS AND TECHNOLOGY CONFERENCE (ECTC 2021), 2021)
CRIS-Team WoS Importer:2021-10-29

Reliable packaging technologies for power electronics: Diffusion soldering and heavy copper wire bonding - Syed Khaja, Aarief Hussain; Kästle, Christopher; Franke, Jörg (2013 3rd International Electric Drives Production Conference, EDPC 2013, 2013)
Production of a reliable power module capable of achieving higher switching frequencies and higher junction temperatures is limited by the present assembly and packaging methods, mostly in the areas of the die-attach and the top level interconnections. The present study aims to display the advances in packaging technologies of diffusion soldering and heavy copper wire bonding in the view of material characterization, process optimization and quality improvement. In diffusion soldering, the growth of intermetallic phases through thin-layer paste deposition and solder profile optimization with vapor phase soldering were investigated. Solder paste inspections were performed to evaluate the errors during deposition process for thin layers and influences on soldering process and related post-failure modes. In heavy wire copper bonding, the impact of substrates with a mechanically polished surface of reduced roughness was investigated. Furthermore the influence of applying the bond force in a ramp style was examined and inspected with the pull and shear forces. The bond width was also monitored in order to receive a non-destructive quality feature for the process monitoring. All test series were accompanied by a close control of the tool wear-out and its influence on process stability. © 2013 IEEE.
Keywords: copper wire bonding; diffusion soldering; power electronic packaging; process quality; tool wear-out

Resonant method for the measurement of quality of laminated cores - Schneider, Michael; Franke, Jörg (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
Measurement of the electromagnetic properties of soft magnetic materials becomes increasingly important with the demand for more efficiency in electric machines. In addition to the B-H characteristic and the permeability, which is necessary in a FEM program for the calculation of electromagnetic fields for realistic simulation of an electrical machine, today's measurement methods obtain additional information on the quality of finished metal package. Thus, it is possible to identify the engine iron losses, divided into hysteresis and eddy current losses. But under the current state of the art, only samples are provided for checking the quality of laminated cores according to the process steps sheet metal cutting, stacking and packing. For this, several stators are taken from current production and loss measurement is performed. For the measurement of the core loss (toroidal or stator geometry) are each wound a primary and a secondary winding on a sample. The wrapping is done by hand and is therefore very time-consuming. An inline measurement of all stators from a production line is not possible with this effort. To increase the quality and safety of the transparency of the manufactured products a 100% inspection is interesting. In terms of process control of the whole production line a 100% measurement strategy provides the framework for a comprehensive analysis for refining the appropriate feedback variables (tool change times, machine parameters, etc.). The losses should be recorded with the new measurement method during manufacturing and provided to the parent manufacturing control system as information. Thus machine parameters can be adjusted directly or tools are detected at the limit of wear and can be rapidly replaced to ensure a consistently high quality of sheet metal packages. A new method of quality assurance for laminated cores will be presented in this paper.
CRIS-Team Scopus Importer:2023-03-07
Keywords: cutting; iron losses; measurement method; sheet metal; stacking

Review of the direct bonded copper (DBC) process and its adaption to laser powder bed fusion (LPBF) - Stoll, Thomas; Feuerer, Tobias; Hensel, Alexander; Franke, Jörg (Proceedings of SPIE - The International Society for Optical Engineering, 2022)
Additive Manufacturing technologies such as Laser Powder Bed Fusion (LPBF) provide several advantages compared to conventional manufacturing techniques by being cheaper, faster, more flexible and energy efficient. Therefore, they offer a huge potential for electronics packaging. Direct bonded copper substrates are a commonly used substrate technology for power electronics based on copper and alumina. This paper focuses on reflecting the state of the art in DBCtechnology by investigating the parameters different authors used in their experiments and deriving optimal settings based on these results. Furthermore, works addressing the LPBF of copper or laser-based copper processing on ceramics with and without afterward heat treatments were collected. These works were also studied and potentials, challenges as well as prospects for the LPBF-process of the adaption of the DBC-technology are presented.
CRIS-Team Scopus Importer:2022-06-10
Keywords: Additive Manufacturing; Alumina; Copper; Direct Copper Bonded; Electronics; Laser Powder Bed Fusion; Substrate Technology

RF Characterization of the Homogeneity of Sintered Micro- And Nanoparticle Silver Inks for Printed Electronics - Neermann, Simone; Franke, Jörg; Sippel, Mark; Lomakin, Konstantin; Gold, Gerald (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
A significant problem of printed electronics which is hardly considered in science is the inhomogeneous sintering of printed conductive silver micro- and nanoparticle inks. This so called skinning effect as well as its consequences such as accompanying economically suboptimal processes, reduced conductivity, poor surface quality and possible mechanical reliability problems have not yet been investigated. On the other hand, there is a lack of characterization methods to analyze this effect with sufficient accuracy so that it can be observed at all in order to optimize existing processes, materials and thus end products. In this paper the concept of a novel electrical characterization method is presented. The basis of the method is the skin effect, not to be confuse with the skinning of the ink, which describes the penetration of electromagnetic fields in metals that decreases with frequency, thus enabling a correlation between electrical transmission properties and the conductivity profile of printed and sintered lines. This allows for characterization of the effects from various sintering parameters on printed structures by means of appropriate measurement technology. The expected measurement frequencies are in the three-digit MHz range, depending on the DC conductivity. If additional measurements at higher frequencies are available, the penetration depth is so small that conclusions about surface roughness of the sintered structure can be drawn.
CRIS-Team Scopus Importer:2021-04-02
Keywords: characterization; homogeneity; Printed Electronics; RF; sintering

RGB-D-based Human Detection and Segmentation for Mobile Robot Navigation in Industrial Environments - Kedilioglu, Oguz; Lieret, Markus; Schottenhamml, Julia; Würfl, Tobias; Blank, Andreas; Maier, Andreas; Franke, Jörg (16th International Joint Conference on Computer Vision, Imaging and Computer Graphics Theory and Applications (VISIGRAPP 2021), 2021)

Risk Assessment of Data Transfer Between Partners in the Automotive Supply Chain - Bodendorf, Frank; Franke, Jörg (Book of Abstracts - 11th Logistics Management, 2019)
Supplychainsintheautomotiveindustryarecharacterizedbyahighlevelofcomplexityand large amounts of data transferred between partners, particularly between suppliers and manufacturers. Automateddatatransferfromthemanufacturertothesupplierandviceversawithingivensupplychain processes does not only create beneﬁts for both partners but also comprises high risks that cannot be preventedneitherbytermsofcontractnorhighlysophisticatedtechnicalmeasureslikeblockchainbased systems.Ariskassessmentofdataisneededthathelpstoquantifythedam-ageofpotentialdatamisuse beyond the deﬁned supply chain partnership. A model for assessing risks of data transfer and data sharing is introduced and ap-plied to a use case in the automotive supply chain. The assessment process comprises four steps, starting with the identiﬁcationoftheobjectsatriskandendswithrecommendationsforriskmanagement.Thetheoretical and methodological background of risk assessment is outlined. The developed assessment model is explained in detail. The model has been applied to diﬀerent use cases coming from the procurement department of a large automobile manufacturer. The data of the use cases show diﬀerent levels of multidimensional risks and diﬀerent monetary eﬀects of “value at risk”. The experimental results of the model are presented and discussed.<br
Keywords: Risk management; Supply chain data; Value at risk

Risk Assessment of Vehicle Sensor Data as a Vending Object or Service - Bodendorf, Frank; Franke, Jörg (Lecture Notes in Computer Science (including subseries Lecture Notes in Artificial Intelligence and Lecture Notes in Bioinformatics), 2020)
Connected cars generate a huge amount of vehicle data during operation. In the future, the amount of sensor-generated data will continue to increase. The connectivity of the cars, more powerful processors, and improved telematics and navigation systems will allow the amount of data to grow further. Vehicle data provides a basis for a large number of business models. In addition to selling vehicles, automobile manufacturers can generate additional revenue by selling vehicle-generated data as goods or services. First, a typology of vehicle data is described in order to derive value potentials of data products. Motivated by the value perspective, risks in data transfer to third parties are often neglected. In order to assess these risks, a new risk management model for intangible products like data is presented. The main phases of the risk assessment procedure are walked through, outlining possible criteria and metrics in each phase. Finally, the model is demonstrated by evaluating risks of data transfer to third parties in the automotive industry, using the example of vehicle-generated road segment data.
CRIS-Team Scopus Importer:2020-10-16
Keywords: Automotive industry; Business model; Connected car; Cyber physical systems; Data security; Internet of Things; Risk management; Sensor data

Robot-assisted concept for assembling form coils in laminated stator cores of large electric motors - Mahr, Alexander; Mayr, Andreas; Jung, Timo; Franke, Jörg (Procedia Manufacturing, 2019)
Manufacturers of large electric motors, whether for automation or traction purposes, are facing major challenges in high-wage countries. Due to the high proportion of manual activities, a conflict between ensuring profitability and increasing variant variety arises. In order to meet the high demand for large electric motors and to maintain the value added in high-wage countries, manual manufacturing processes must be automated, at least partially. For large electric motors with form coil technology, especially the assembly into the laminated stator core represents a tedious, cost-intensive manual activity. Therefore, this paper deals with the development of a hybrid, robot-assisted assembly system for inserting form coils in laminated stator cores. The combination of manual and automated assembly activities is intended to ensure high productivity while maintaining flexibility. Before realizing such a hybrid assembly system, all process steps are simulated first. In addition, additive manufacturing is used to quickly produce and practically validate different end effector geometries. As shown by the final prototypical implementation, a major portion of the assembly of form coils can be carried out fully automatically by a dual-arm robot. Remaining challenges could be addressed by adding a vision system and thereby making use of novel machine learning techniques.<br
Keywords: Hybrid assembly system; Automation; Dual-arm robot; Electric motor production; Form coils; Stator production

Robot-Based Assembly of Cover-Plates - Kühl, Alexander; Franke, Jörg (EMCW Expo, 2014)
Keywords: E|DRIVE; Robot; Stator; Motor; Electric Motor

Robot-based assembly of stators - Kühl, Alexander; Franke, Jörg (2013 3rd International Electric Drives Production Conference, EDPC 2013, 2013)
Keywords: Automated Winding Assembly; Robot-based; Cover; Stator

Robot-Based Assembly of Stators – Methods and Tools to Assembly Windings and Coverplates Robotergestützte Montage von Elektromotorstatoren: Methoden und Werkzeuge zur Montage von Wicklungen und Deckschiebern - Kühl, Alexander; Höft, Annika; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2014)

Robot-based assembly of stator-windings - Kühl, Alexander; Günther, Stefan; Franke, Jörg (Electrical Manufacturing and Coil Winding Expo 2010-2013, 2013)
Keywords: Automated winding assembly; Stator; Robot-based

Robot-based assembly of stator-windings Roboterbasierte Wicklungsmontage: Flexible Statormontage unter Anwendung ambidexterer Kinematiken - Kühl, Alexander; Franke, Jörg (wt Werkstattstechnik - Online, 2013)

Robot-based automated production of wrapped connections with single solid round wires - Hefner, Florian; Herbert, Meike; Sjarov, Martin; Süß-Wolf, Robert; Franke, Jörg (Production at the leading edge of technology, 2019)
The solderless wrapping process is an electrical connection technology. It is mainly used in applications which require high reliability, such as the aerospace industry. A single solid conductor is wrapped around a connecting terminal. The process is currently being realized manually and the worker's qualification highly determines the overall process quality and efficiency. The challenges of this specific task include the handling of the flexible wire, the production process of standard-conforming wrapped connections and the required positioning accuracy of the tool relative to the wrappost. An automation of the production process is essential to meet the increasing quality and efficiency requirements of modern production environments, however, available solutions still highly rely on the operator and therefore lack the aspired automation degree. To enable the automated production of wrapped connections, a lightweight robot is equipped with several components. In this paper, the design of the whole system, including the newly developed robotic end-effector, is presented. The main components are two wrapping tools, each driven by an electric motor and attached to an electric slide. The device can be moved onto the wrappost extending the electric slide. A wire feeder realizes the conveying movement of the wire. Moreover, an optical sensor is used to determine the wrappost's position and orientation. The newly developed system enables the automated production of wrapped connections conforming to standards.<br
Keywords: wrapped connections; robot-based automation; flexible manufacturing

Robot-based Forming of Hairpin Winding - Kühl, Alexander; Franke, Jörg (2021 IEEE International Electric Machines and Drives Conference, IEMDC 2021, 2021)
Rotating electrical machines receive an innovative push due to the demands which are made on traction drives. Thus, machines with high power density are required which are produced cost-effectively in large series production. In order to meet these requirements, the use of stators with hairpin winding is a suitable approach, as they have the potential to achieve improved copper filling factors in the stator slots. Furthermore, this technology is also seen as an opportunity to improve the complex and often non-reproducible winding technologies by means of bending, assembly and joining processes. In the design of electric drives, the influences of deviations of the manufacturing processes on the performance are usually not considered. This applies in particular to hairpin winding technology, the manufacture of which requires a large number of bending and contacting operations. These process steps can change the electrical properties of the winding, which changes the behavior of the electrical machine. For this reason, one goal of research at the Institute for Factory Automation and Production Systems (FAPS) is to investigate flexibly automated and reproducible processes for the production of hairpin winding. In the context of the paper, special attention is set on the robot-based forming process and the process-safe conveying of the wire.
CRIS-Team Scopus Importer:2021-08-27
Keywords: bending; electric motor; flexible automation; forming; hairpin; production; robot-based; winding

Robot-based Production of Electric Motors with Hairpin Winding Technolgy - Kühl, Alexander; Riedel, Andreas; Gläßel, Tobias; Masuch, Michael; Franke, Jörg (International Conference on Intelligent Automation and Robotics (ICIAR'19), 2019)

Robot-based Sample Tube Handling for Automated Pre- and Post-processing of SARS-CoV-2 PCR Tests - Seßner, Julian; Reitelshöfer, Sebastian; Lieret, Markus; Springs, Konstantin; Franke, Jörg (54th International Symposium on Robotics, ISR Europe 2022, 2022)
The SARS-CoV-2 pandemic worldwide has led to millions of infections with partly severe complications and death. The diagnosis is based on a PCR test of a saliva sample and is carried out in specialised laboratories. While the actual PCR analysis is usually automated, sample preparation and post-processing often involve manual handling steps. The paper presents an approach for robot-based pre- and post-processing of sample tubes. A seven-axis industrial robot is equipped with a multifunctional gripper and enabled for the application. In addition, machine-learning based image processing solutions are be integrated to increase flexibility and robustness. The implementation shows the feasibility of the approach in principle. The achieved cycle time does not fulfil the set requirements completely, but the implementation provides numerous approaches for optimisation.
CRIS-Team Scopus Importer:2022-09-16

Roboterassistenz in der Behindertenwerkstatt: Intuitiv bedienbare, sichere und flexible Zusammenarbeit mit Industrierobotern - Leutert, F.; Ramer, Christina; Pirkl, G.; Bahle, G.; Poxrucker, A.; Dresselhaus, M.; Ziegler, Christoph; Schilling, K.; Franke, Jörg; Lukowicz, P. (wt Werkstattstechnik - Online, 2014)
For a successful collaboration between humans and robotic assistants in a shared workspace, users must be enabled to intuitively understand robotic data and work processes, to easily operate the robot while being protected from harm by safety systems. This article introduces an assistance system employed in sheltered workshops that achieves these goals using Augmented Reality, novel input devices, and automatic collision avoidance.
Keywords: B|Mech

Robotergestützte Sortierung radioaktiver Abfälle zwecks volumenoptimierter Konditionierung - VIRERO - Havenith, Andreas; Dürr, Martin; Helmes, Christopher; Krycki, Kai; Hansmann, Tim; Hansmann, Bengt; Reisenhofer, Florian; Simons, Frederic; Wangnick, Martina; Kohn, Sebastian; Querfurth, Frank; Sommer, Oliver; et al. (15th International Symposium “Conditioning of Radioactive Operational & Decommissioning Wastes” including 15th Status Report of BMBF “Decommissioning and Dismantling of Nuclear Facilities“, 2021)
Seit dem 01. Januar 2020 dürfen kernkraftwerksbetreibende Unternehmen (EVU), gemäß dem Gesetz zur Neuordnung der Verantwortung in der kerntechnischen Entsorgung, vernachlässigbar wärmeentwickelnde Abfälle an die BGZ Gesellschaft für Zwischenlagerung mbH übergeben, sofern diese fachgerecht verpackt sind. Bis zur geplanten Inbetriebnahme des Endlagers Konrad obliegt die Verantwortung für die Zwischenlagerung der BGZ. Der „Planfeststellungsbeschluss für die Errichtung und den Betrieb des Bergwerkes Konrad in Salzgitter“ vom 22. Mai 2002 sieht ein einlagerbares Abfallvolumen von 303.300 m³ vernachlässigbar wärmeentwickelnder radioaktiver Abfälle vor. Durch das begrenzte verfügbare Volumen des Endlagers ist eine Volumenoptimierung der endzulagernden Abfälle durch die EVUs als Verursacher wirtschaftlich attraktiv. In dem Projekt VIRERO (VIrtual REmote RObotics for Radiometric Sorting, 10/2020 – 09/2023) wird eine solche Volumenoptimierung durch eine teleoperierte Zerlegung und Neusortierung radioaktiver Abfälle mit hohen Ortsdosisleistungswerten (ODL-Werten) entwickelt und erprobt. Durch Zerlegung und Neusortierung lassen sich insbesondere hochradioaktive Abfallstücke (Hotspots) vom restlichen Abfall absondern, wodurch eine volumenoptimierte Verpackung des Abfalls erwirkt werden kann. Die Zerlegung und Sortierung des Abfalls erfolgt mittels innovativer Robotertechnik, welche mittels immersiver Augmented Reality und Virtual Reality Verfahren (AR/VR) gesteuert wird. Hierdurch entfällt die Handhabung durch mechanische Fernmanipulatoren. Die Separation der Hotspots und die Sortierung basiert auf einer Vielzahl von ortsaufgelösten Dosisleistungsmessungen oder ortsaufgelösten gammaspektrometrischen Messungen und einer hierauf aufbauenden Aktivitätsrekonstruktion aller Abfallteile. Diese Aktivitätsrekonstruktion wird durch die Kopplung von innovativer Kernstrahlungsmesstechnik mit industriell bewährter Laserscan-Technik erreicht.<br
Keywords: Decommissioning; Radioactive Waste Conditioning; Teleoperation; Virtual Reality; Augmented Virtuality

Roboter sind leicht zu integrieren - Schäffer, Eike (2021)
Das Robotik-Portal Robotop führt zu einem minimalen Planungsaufwand. Der Baukasten inklusive Beispielanwendungen dient als Basis für eine flexible Integration von Robotik-Applikationen. Über eine Datenbank mit Regelwerk, Attributen und Bedingungen wird die Planung zusätzlich abgesichert und automatisiert. Vor der Installation können die Lösungen durch 3D-Simulationen auf ihre Passfähigkeit untersucht werden. Den Einsatz von Robotern in der Produktion können Unternehmen damit ohne Expertise und wie bei einem Baukastensystem planen, konfigurieren und simulieren.<br

Roboter werden biomechatronische Assistenten - Reitelshöfer, Sebastian; Merz, Nina; Blank, Andreas; Kedilioglu, Oguz; Martin, Sina; Seßner, Julian; Franke, Jörg (2021)
Keywords: Biomechatronik; Human-Centered Robotics

Robotic automatization of handling and contacting the ends of windings for mounting electric drives - Kühl, Alexander; Lebender, Johannes; Franke, Jörg (Lecture Notes in Engineering and Computer Science, 2016)
The connecting process is still one of the most time-consuming processing steps in the production of electric drives. For this reason, the E|Drive-Center at the Institute for Factory Automation and Production Systems (FAPS) from Friedrich-Alexander University Erlangen-Nuremberg (FAU) is researching a solution centered on the flexible automation of this process. This paper examines the possibility of automating the contact of windings' ends in an asynchronous motor with a universal, ambidextrous robot using a contact base. Here, the related ends of the enameled copper wires are connected before plugging in the power supply. In doing so, the robot saves the ends directly after manufacturing the coils in a winding machine and transports them to the face side of the stator. The final connection with the motor periphery is implemented with termination clamps whereby a blade cuts through the wire insulation and produces an electrical connection, while the wiring for the motor concept is actualized by a wiring institution in the form of a plastic ring with printed conducting paths. This form of contacting the ends of windings while mounting an electric drive with a universal, ambidextrous robot has the potential to save time and improve process stability.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Automation; Connecting; robot; Contacting; Electrical drive production; Wiring

Robotic based Assembly of insulating Sleeves onto Winding Coil Ends of Electric Drive Stators - Mahr, Alexander; Mathea, Philipp; Vogel, Alexander; Morello, Andreas; Franke, Jörg; Kühl, Alexander (13th International Electric Drives Production Conference (E|DPC), 2023)
In the production of electrical motors based on the insertion technology, the stator, with a share of 35% of the total costs, is the most expensive component and offers a variety of automation possibilities. In the field of secondary insulation, the application of insulating sleeves onto the stator winding coil ends is usually carried out in manual assembly stations, even in highly automated production lines. This process is a tedious and cost-intensive manual activity. The developments presented in this work show an automated assembly approach for this production step. This invention is based on an industrial robot assembly station that, among other processes, applies commonly used insulation sleeves to the respective winding parts in the stator winding head. With an initial process analysis and the construction of a prototype machine, the basic suitability as an automatable process solution for the assembly of insulation sleeves is presented.<br
Keywords: Insulation; Technological innovation; Windings; Stator windings; Prototypes; Production; Manuals

Robotic-based Automatization of Handling and Contacting of the Ends of Windings for the Mounting of Electric Drives - Kühl, Alexander; Franke, Jörg; Lebender, Johannes (WCECS 2016 - World Congress on Engineering and Computer Science 2016, 2016)
Keywords: E|DRIVE

Robotics simulation – A comparison of two state-of-the-art solutions - Zwingel, Maximilian; May, Christopher; Kalenberg, Matthias; Franke, Jörg (ASIM 2022 Proceedings Langbeiträge, 2022)
Simulation plays a significant role in development and deployment of robotics systems. Depending on the planned tasks, different functionalities shift into focus. For mobile robotics systems using the Robot Operating System (ROS), Gazebo has been the goto solution for simulating behavior, sensors, and interaction with environments for many years. With the availability of numerous novel solutions, a comparison of the different strengths from a use-case perspective becomes necessary. In our paper, we compare Gazebo and NVIDIAs Isaac Sim in the context of ROS-based autonomous mobile robots. Special attention is given to the integration of the simulators in the ROS-environment and their ability in regards to sensor simulation. This paper aims to provide a comparison between different features in Gazebo and NVIDIA Isaac Sim for simulating mobile robots and sensor systems. <br

Robotic Technologies for Volume-Optimized Conditioning of Radioactive Waste – VIRERO - Blank, Andreas; Havenith, Andreas; Kohn, Sebastian; Querfurth, Frank; Zwingel, Maximilian; Metzner, Maximilian; Franke, Jörg (ICOND 2020 Conference Proceedings, 2020)
An appropriate conditioning of radioactive waste is in the focus of institutions responsible for disposal. In 2018, the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety provided an overview of the existing stock of radioactive waste respectively waste to be disposed. Therein a forecast is given regarding the expected volume of waste, indicating that the disposal volume of Konrad repository (303.000 m³) is just sufficient. Due to limited capacities a volume-optimized conditioning is advantageous and preferable. However, post-conditioning of waste, especially of waste with higher dose rates, requires remote handling. Thereby, compliance to the waste acceptance criteria for disposal of Konrad must be ensured. In cases without an adequate waste declaration or if discrepancies are detected by a non-destructive characterization, waste contingents must be extracted, characterized, re-sorted and re-packaged. Even for properly documented contingents, reconditioning may save costs by increasing packing densities. Within the R&D-project VIRERO (VIrtual REmote RObotics for Radiometric Sorting, 10/2020 – 09/2023) a robot-based system for volume-optimized conditioning and testing is realized. The utilized disruptive robotic and radiological technologies enable efficient dismantling, handling and radiological waste sorting. Thereby, a spatially resolved radiological characterization is combined during image processing with complementary cameras. An augmented virtuality teleoperation provides the accurate simultaneous control of multiple robots through a single operator. For improved efficiency while maintaining high safety standards, the automated conditioning of highly individual waste and the relieve of operator workload are within the research scope of this projec
Keywords: Nuclear Decommissioning; Waste Characterization; Conditioning; Robotic Sorting; Teleoperation

Robotiklösungen im Baukastenprinzip für den Mittelstand - Schäffer, Eike; Schulz, Jan-Peter; Franke, Jörg (2019)
Robotiklösungen versprechen Effizienzsteigerungen und die Entlastung von Arbeitnehmern bei körperlich anstrengenden und gefährlichen Tätigkeiten. Außerdem ermöglichen sie den Erhalt der Produktion in Deutschland. Die Automatisierung von manuellen Tätigkeiten gehört deshalb zunehmend zum Alltag in deutschen Unternehmen. Vor allem für kleinere Unternehmen ist allerdings der hohe Aufwand problematisch. Das Projekt ROBOTOP hat deshalb eine flexible Webplattform entwickelt, die es ermöglicht „baukastenartig“ Hardware-Komponenten zu individuellen Automatisierungslösungen zu kombinieren.<br
Keywords: ROBOTOP; Webplattform; Robotik; Automatisierungslösung; KMU; Konfiguration

Robust Obstacle Mapping for Visually Impaired Jogger on Less Structured Paths - Seßner, Julian; Ramer, Christina; Manert, Moritz; Reitelshöfer, Sebastian; Franke, Jörg (2019 IEEE/SICE International Symposium on System Integration, 2019)
This paper presents robust mapping of obstacles for an assistive system for blind and visually impaired jogger. The missing visual perception is substituted with a 3D stereo camera, capturing color and depth information from the environment. It is integrated into a lightweight backpack together with a single board computer. This paper focusses on the obstacle detection and mapping using the v-disparity method. To enhance the robustness of the mapping algorithm a roll angle detection and compensation is implemented. The algorithms are evaluated in different environments and proved their feasibility. The framerate is sufficient to detect obstacles in tim

Rolling-reactive Optimization of Production Processes in a Calcium Silicate Masonry Unit Plant Using Online Simulation - Donhauser, Toni; Ebersbach, Tobias; Franke, Jörg; Schuderer, Peter (Procedia CIRP, 2018)
In case of concatenated, complex material flow structures such as those in calcium silicate masonry unit plants, plan deviations pose a major challenge for an efficient order processing in production. In order to overcome the separation between the planning and operational levels in traditional production planning and control systems, this paper presents a validated concept to react immediately to critical events while maintaining efficiency using a modular, rolling-reactive optimization tool. A substantial difference to conventional rescheduling models is the intensive integration of event-discrete simulation, which delivers more realistic results and reduces the threat of an obsolete model due to simple modellin
Keywords: Simulation-based Optimization; Discrete-event Simulation; Decomposition; Algortihms; Calcium Silicate Masonry Unit; Rolling-reactive Optimization; Digital Shadow; Digital Twin

ROS-based validation and system integration of two different electromyography sensor hardware for control of mechatronic systems - Yoo, In Seong; Becker, Sebastian; Vu, Tien Huy; Franke, Jörg (Biomedizinische Technik. Biomedical engineering, 2016)
Keywords: B|Mech; Electromyography (EMG); Prothetik

Rotary cutting as an alternative method in the processing of electrical steel strip: Geometric and kinematic determination of the process setup - Hubert, Markus; Franke, Jörg; Hackert, Jürgen; Rosenow, Hannes (5th International Conference on Electric Drives Production, EDPC 2015, 2015)
Improving the efficiency in production is always the aim. In many applications, where progressive stamping approaches the technological limits, rotary cutting is successful. Relevant applications to name are the processing of paper, card boxes, packaging and simple perforated steel profiles. The main limiting factors of the stamping technology are the accelerations and decelerations in sheet feed and stamping motion. In contrast rotary cutting is a continuous process which leads to greater speeds and higher output. While performing the electrical steel strip between two cylindrical tools in stamp and die arrangement, the laminations are being cut out. Rotary cutting in the manufacture of laminations is a great challenge and a research topic at the Bavarian Technology Center for Electric Drives at the FAU. This paper provides the main technological differences between progressive stamping and rotary cutting regarding the process structure. Furthermore the geometric and technical parameters of the rotary cutting process are described mathematically. Finally the correlation of process parameters are identified.
Keywords: Electrical Sheet Processing; Rotary cutting; Tooling

Rotary Cutting of Electrical Steel Laminations—An Innovative Method for Manufacturing Electrical Machines - Hubert, Markus; Franke, Jörg (Electric Power Components and Systems, 2016)
Improving the efficiency in production is always a primary goal. In many applications where progressive stamping approaches the technological limits, rotary cutting is successful. Relevant applications include the processing of paper, card boxes, packaging, and simple perforated steel profiles. The main limiting factors of stamping technology are the accelerations and decelerations in sheet feed and stamping motion. In contrast, rotary cutting is a continuous process that leads to higher speeds and greater output. While performing the electrical steel strip between two cylindrical tools in a stamp and die arrangement, the laminations are cut out. Rotary cutting for the manufacture of laminations is a great challenge and a research topic at the Bavarian Technology Center for Electric Drives at the Friedrich Alexander University.
Keywords: electrical steel processing; rotary cutting

Schlanke Informationsflüsse für eine effiziente Produktion - Risch, Florian; Berndt, Rüdiger; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2011)
UnivIS-Import:2015-03-09:Pub.2011.tech.IMMD.IMMD7.schlan

Schlussbericht zu dem Teilvorhaben "Automatisierte Fertigungstechnologien zum Biegen, Montieren und Schalten von innovativen Formspulenwicklungen" im Verbundprojekt "PRO-E-Traktion" - Gläßel, Tobias; Masuch, Michael; Weigelt, Michael; Kühl, Alexander; Franke, Jörg (2020)
Schlussbericht zu dem Teilvorhaben "Automatisierte Fertigungstechnologien zum Biegen, Montieren und Schalten von innovativen Formspulenwicklungen" im Verbundprojekt "PRO-E-Traktion" ("Automatisierte und robuste Produktionssysteme für E-Traktionsantriebe") Gefördert durch das Bundesministerium für Wirtschaft und Technologie, begleitet durch DLR e. V. Projektträger Förderkennzeichen: 01MX15011F Die Formspulentechnologie gilt als Schlüssel zur Realisierung leistungsdichter elektrischer Traktionsantriebe. Darüber hinaus stellt sie eine Möglichkeit dar, die gegenwärtig schlecht kontrollierbaren Wickelverfahren durch stabilere Biege-, Montage- und Fügeprozesse zu ersetzen. Allerdings waren zum Zeitpunkt des Projektbeginns die benötigten Technologien weder identifiziert, noch entwickelt und qualifiziert. Hier setzt das vorliegende Projekt an, indem es technologische Alternativen für die durchzuführenden Prozessschritte identifiziert und priorisiert. Basierend darauf werden vollautomatisierte Prozessketten zur Herstellung von Statoren mit Hairpinwicklung in unterschiedlichen Stückzahlszenarien konzipiert und in Simulationen validiert. Um darüber hinaus Potentiale alternativer Arten offener Formspulenwicklungen bewerten und gegenüberstellen zu können wird eine Referenzmaschine auf diese übertragen und eine Bewertungssystematik entwickelt und angewandt, in deren Ergebnis die produkt- und fertigungsseitigen Potentiale von Hairpinwicklungen bestätigt werden. Die identifizierten Kernprozesse des Biegens, Montierens sowie der Kontaktierung werden grundlegend analysiert und auf dieser Grundlage die Industrialisierbarkeit der Prozesse abgeleitet. Für die Herstellung der Hairpins zeigt sich eine Kombination des Rotationszugbiegeverfahrens mit einem Gesenkbiegeverfahren als aussichtsreich. Zur Montage der Hairpins in den Stator werden unterschiedliche Konzepte ausgearbeitet und validiert, wobei die Wichtigkeit einer geeigneten Führung der Formspulen herausgearbeitet wurde. Es zeigt sich, dass der Kontaktierung eine wesentliche Rolle in der Prozesskette zukommt, wobei gezeigt wird, dass sich mit einer Kombination aus laserbasierten Isolationsabtrag und Laserstrahlschweißen ein geeigneter Kontaktierungsprozess ableiten lässt. Die erzielten Ergebnisse tragen zu einer Senkung der Hürde bei der vollautomatisierten Herstellung von Statoren mit Formspulen-wicklung bei, da sie die Technologieauswahl, Prozessentwicklung sowie Anlagenplanung maßgeblich vereinfachen Bar-wound windings are regarded to be a key technology to realize electric traction drives with a high power density. Additionally, they provide an opportunity to replace recent winding technologies, that are characterized by a poor controllability, with bending, assembling and joining processes featuring a better process stability. Nevertheless, at the beginning of this project the technologies necessary were neither identified nor developed and qualified. To deal with these issues, the present project identifies and assesses technological alternatives for the process steps necessary. On that basis fully automated production chains for the production of stators with hairpin windings for different production volumes are designed and validated in simulations. Beyond that, the reference winding of this project is conveyed on alternative kinds of bar-wound windings. To be able to compare the resulting concepts, a rating system for bar-wound windings is developed that confirms the potentials of hairpin windings. The key process steps of bending, assembling and contacting identified in this project are analyzed fundamentally and based on these results, industrialization capabilities are derived. For the production of the hairpins, a combination of rotary draw bending and die bending proves to be promising. Different concepts to assemble the hairpins to the lamination are developed and analyzed. It is determined, that a suitable guidance of the bar-wound coil is necessary in any case. The analysis of the contacting process showed, that this process plays an important role in the process chain. Combining a laser based process for the removal of the insulation with a laser welding process is a suitable possibility to realize a reproducible contacting process. The results achieved contribute to a reduction of obstacles for the implementation of a fully automated production of stators with bar-wound windings, as they facilitate the selection of suitable technologies, the development of processes necessary and the planning of production facilities.
Keywords: bar-wound windings; Bending; Biegen; electric mobility; Elektromobilität; Elektromotor; enamelled wire; FKZ: 01MX15011F; Formspulenwicklung; Hairpin; hairpin windings; Hairpinwicklung; INSULATION; Isolation; Lackdraht; Laserschweißen; production technologies; Produktionstechnologien; Pro-E-Traktion; Stator; traction drives; Traktionsantriebe

Science-Fiction Movies as an Indicator for User Acceptance of Robots in a Non-Industrial Environment - Merz, Nina; Huber, Maximilian; Bodendorf, Freimut; Franke, Jörg (SIGMIS-CPR 2020 - Proceedings of the 2020 Computers and People Research Conference, 2020)
CRIS-Team Scopus Importer:2021-04-19
Keywords: Human-Robot-interaction; Humanoid robot; Product development; Research in progress; Robot; Science-fiction; Technology acceptance

Scientific Approaches and Methodology to Determine the Value of Data as an Asset and Use Case in the Automotive Industry - Bodendorf, Frank; Dehmel, Klaus; Franke, Jörg (2022)
From a theoretical perspective data does not constitute a traditional business asset. Existing valuation approaches are either sector specific or still unexplored. In modern businesses the value-adding use and monetization of existing “big data” represents one of the greatest potentials in the context of digital transformation. This paper aims at reviewing methods and developing an integrated methodology for the value determination of data in general and for use in the manufacturing industry in particular. Therefore, the general state of research in data value assessment is investigated by a broad literature analysis. Based on the identified general principles, methodological requirements for data value determination are compiled. A new methodology for data evaluation is developed and applied to four use cases coming from the automotive industry. The results show that the methodology can be used in different contexts and thus enables managers to explore the most promising use cases for data-driven business.<br
Keywords: Value; Success; and Performance Measurements of Knowledge; Innovation; and Entrepreneurial Systems; automotive industry; case study; data value determination; evaluation methods

Segmentierte Rotoren in leistungsstarken Hybridantrieben - Albrecht, Thomas; Hubert, Markus; Franke, Jörg; König, Werner (Antriebstechnik, 2013)

Selective Laser Melting for Additive Manufacturing of High-Temperature Ceramic Circuit Carriers - Syed Khaja, Aarief Hussain; Franke, Jörg (66th IEEE Electronic Components and Technology Conference, ECTC 2016, 2016)
Additive manufacturing (AM) is one of the key technologies which poses as an energy and resource efficient alternative to conventional subtractive and formative technologies. In this contribution, additive layered manufacturing mainly selective laser melting (SLM) is investigated to check the potential for substrate manufacturing, system integration and packaging concepts in electronic systems. The challenge for an optimal mechatronic integrated device design is to simultaneously consider both the application-specific requirements and to integrate advantages of molded interconnect device (MID) technology. This work focuses on the process development for the generation of conductive patterns on ceramic substrates by SLM. The process influencing parameters such as laser power, velocity and scan concepts were tested to check the bonding characteristics. The obtained layer thicknesses and the corresponding process-generated failure mechanisms and the mechanical stability are presented. The potential of SLM for high temperature applicability is further discussed.
Keywords: Additive manufacturing; Ceramic substrates; Electronics production; High temperature; Mechatronic integrated devices; Molded interconnect devices; Selective laser melting

Selective light sintering of Aerosol-Jet printed silver nanoparticle inks on polymer substrates - Schütz, Klaus; Hörber, Johannes; Franke, Jörg (AIP Conference Proceedings, 2014)
Printing silver nanoparticle inks to generate conductive structures for electronics on polymer substrates has gained increasing relevance in recent years. In this context, the Aerosol-Jet Technology is well suited to print silver ink on 3D-Molded Interconnect Devices (MID). The deposited ink requires thermal post-treatment to obtain sufficient electrical conductivity and adhesion. However, commonly used oven sintering cannot be applied for many thermoplastic substrates due to low melting temperatures. In this study a new sintering technology, selective light sintering, is presented, based on the focused, continuous light beam of a xenon lamp. Sintering experiments were conducted with Aerosol-Jet printed structures on various polycarbonate (PC) substrates. Especially on neat, light transparent PC, silver tracks were evenly sintered with marginal impact to the substrate. Electrical conductivities significantly exceed the values obtained with conventional oven sintering. Adhesive strength is sufficient for conductive tracks. Experiments with non-transparent PC substrates led to substrate damage due to increased light absorption. Therefore a concept for a variation of light sintering was developed, using optical filters. First experiments showed significant reduction of substrate damage and good sintering qualities. The highly promising results of the conducted experiments provide a base for further investigations to increase adhesion and qualifying the technology for MID applications and a broad spectrum of thermoplastic substrates. © 2014 American Institute of Physics.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Aerosol-Jet Printing; Light Soldering System; Molded Interconnect Devices (MID); Silver Ink; Sintering

Selective magnet assembly assisted by an automated warehouse system: Algorithms, performance and industry 4.0 readyness - Meyer, Alexander Wilhelm; Mayr, Andreas; Malygin, Nikolay; Zhang, Yixiao; Franke, Jörg (2017 7th International Electric Drives Production Conference (EDPC), 2017)
Permanent magnet synchronous motors (PMSM) suffer, depending on the topology, from quality deviations of the used magnets. These can result in insufficient running characteristics, such as low power output, low energy efficiency, consequently excessive heat, strong vibrations and noise. Especially topologies, such as halbach array rotors, are strongly reliant on an even magnetic field with ideally a full flux concentration in the working air gap. As a solution for cost efficient manufacturing of these special topologies, requiring a 100 % test of magnets, an algorithm for optimized warehouse management and a graphic industry 4.0 ready user interface for the FAPS magnet intralogistics warehouse system is presented. As an example and first suggestion for compensation of magnetic fields in radial flux topologies, a vector addition based algorithm for the compensation of spatial magnetic moment deviations is developed.<br
Keywords: magnet assembly; permanent magnet synchronous motor; PMSM; magnet logistics; warehouse system

Self-calibration method for a robotic based 3D scanning system - Wagner, Maximilian; Heß, Peter; Reitelshöfer, Sebastian; Franke, Jörg (2015 IEEE 20th Conference on Emerging Technologies Factory Automation (ETFA), 2015)
This paper describes a method for extrinsic sensor calibration for a 2D laser profile sensor on a robot arm used as a robot based 3D scanning system. In order to establish a relationship between the sensor measurements and the robot positions, the transformation between the robot flange and the sensor reference frame are determined. The developed calibration method is implemented as an automated self-calibration. It is based on the use of a pin as a fixed reference. The robot is aligned to the tip of the pin automatically with certain orientations. The sensor transformation is calculated based on six recorded robot positions. Finally, the accuracy of the calibration is determined with an additional robot position.
Keywords: calibration; manipulators; optical scanners; self-adjusting systems; 2D laser profile sensor; automated self-calibration; extrinsic sensor calibration; robot arm; robot flange; robotic based 3D scanning system; self-calibration method; sensor measurements; sensor reference frame; sensor transformation; Accuracy; Calibration; Robot kinematics; Robot sensing systems; Solid modeling; Three-dimensional displays

Self-learning RRT* Algorithm for mobile robot motion planning in complex environments - Zhang, Xu; Lütteke, Felix; Ziegler, Christian; Franke, Jörg (Advances in Intelligent Systems and Computing, 2016)
RRT* is a practical and efficient incremental sampling-based motion planning algorithm. However, its searching ability is quite inefficient in some cases, due to relying on uniform random sampling like other RRT-based algorithms without taking the environment information and prior knowledge into account, which particularly leads to many sampling failures or generation of useless nodes in complex environments. In this paper, we propose an extension of RRT* based on a self-learning strategy and a hybrid-biased sampling scheme to improve the planning efficiency. By taking advantage of the prior knowledge accumulation and cost estimation, the searching tree has higher probability and success rate to extend in difficult areas. We also demonstrate the performance of our algorithm by building some simulation environments for our mobile robot and conclude with the results compared with RRT*.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Biased sampling; Mobile robot; Motion planning; RRT*

Semantic Meta Model for the Description of Resource and Energy Data in the Energy Data Management Cycle - Brandmeier, Markus Andreas; Brossog, Matthias; Franke, Jörg (Applied Mechanics and Materials, 2017)
Energy efficiency is a critical competitive factor. Transparency of energy consumption is the key for increasing efficiency of production. For this purpose, existing energy data management systems collect data such as power, gas or water consumption on field level, store them in databases, and generate reports. However, the identification of energy saving potentials and the definition of efficiency measures is carried out by energy experts and thus is dependent on a person’s knowledge. The documentation of knowledge about saving potentials and measures does not take place and relations among data and knowledge of various domains are not captured. In this paper, we provide an approach that allows the holistic capture and description of data and knowledge relations. Through the use of an ontology-based meta model, consumption data can be augmented with information about time and place of capture, data type, intended purpose and permissions, as well as interfaces to other systems and relations to knowledge elements. The semantic model is able to capture relevant requirements of all information demanders within the energy data management cycle. Therefore, the model is capable of detecting efficiency deficits and retrieving relevant energy efficiency measures within a knowledge base. Thus, energy consumption data can be efficiently used and knowledge about efficiency can be sustainably preserved.
Keywords: Energy Data Management; Semantic Data Description; Knowledge Representation

Semantic part segmentation of spatial features via geometric deep learning for automated control cabinet assembly - Bründl, Patrick; Scheffler, Benedikt; Stoidner, Micha; Nguyen, Huong Giang; Baechler, Andreas; Abrass, Ahmad; Franke, Jörg (Journal of Intelligent Manufacturing, 2023)
Industries with batch size one manufacturing philosophies for highly customized products have been largely limited in manufacturing automation. The control cabinet industry is particularly affected by this problem during the mounting and wiring of components due to high variety, variance, and complexity of components as well as handling tasks. Rapid advances in the field of machine learning are opening new possibilities for automating previously manual processes. This paper proposes a concept for identifying geometric features of electrical components that starts from STEP files and transforms them into modular metrics relevant to build a digital twin and (automatic)manufacturing. The architecture is tested on a self-aggregated and processed dataset of control cabinet components and achieves an average dice score of 65.27% and an intersection over union of 51.41% across all segmentation classes. In addition to semantic part segmentation of the components, the cluster, volume and surface centroids, the normal vectors and the size of each feature are computed. The paper evaluates the suitability of cutting-edge techniques such as diffusion as well as established deep learning architectures. The result is a hybrid end-to-end inference pipeline suitable for general spatial assembly processes.
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Keywords: Control cabinet; Digital twin; Geometric deep learning; Semantic part segmentation; Surface mesh processing

Semantic Segmentation of Multi-Channel Polycrystalline Structure Micrographs Using Convolutional Neural Networks - Selmaier, Andreas; Lutz, Benjamin; Kißkalt, Dominik; Boernicke, Simon; Fuerst, Jens; Franke, Jörg (20TH IEEE INTERNATIONAL CONFERENCE ON MACHINE LEARNING AND APPLICATIONS (ICMLA 2021), 2021)
Due to ever-increasing data availability, computational power, and algorithmic advances, machine learning enables various novel industrial applications. A field with particularly strong potential for machine learning is computer vision. As part of that area, semantic segmentation refers to a process that links each pixel of an image to a corresponding class. In this task, deep learning has outperformed traditional image processing techniques as well as other classical machine learning techniques and therefore has become the new standard approach. Convolutional neural networks (CNN) are a specific form of deep neural networks, which exploit spatial information for the classification of pixels. This paper presents an approach in which CNNs are optimized and applied to a semantic segmentation problem by using multichannel microscopic images of tungsten flat emitters to determine their surface conditions. These are of strong interest since they may reveal information about potential defects and the life expectancy of the emitter, which is an indispensable component of X-ray tubes as they are used in medical applications.<br
CRIS-Team WoS Importer:2022-05-27
Keywords: manufacturing; machine learning; computer vision; semantic segmentation; visual inspection; X-ray flat emitters; medical devices

Semantische Kommunikationsschnittstellen zur Zustandsüberwachung im Karosseriebau: Serviceorientierte Architekturen für die Maschinendiagnose in vernetzten Produktionssystemen - Fleischmann, Hans; Kohl, Johannes; Blank, Andreas; Schacht, Michael; Fuchs, Jonathan; Franke, Jörg (wt Werkstattstechnik - Online, 2016)
Industry 4.0 technology promises to support the fulfillment of complex production tasks. Even today, historically grown industrial communication networks prevent an efficient implementation of smart factory principles, especially due to a lack of semantics and the strict communication along the existing layers of the automation pyramid. This publication focuses on the development of semantic communication interfaces using the example of the digitalization of the vehicle body construction at the Audi AG.
Keywords: Industrie 4.0; Automatisierung; Mensch und Technik

Semantische Kommunikationsschnittstellen zur Zustandsüberwachung im Karosseriebau; Serviceorientierte Architekturen für die Maschinendiagnose in vernetzten Produktionssystemen - Fleischmann, Hans; Kohl, Johannes; Blank, Andreas; Schacht, M.; Fuchs, Jonathan; Franke, Jörg (wt Werkstattstechnik - Online, 2016)
Industry 4.0 technology promises to support the fulfillment of complex production tasks. Even today, historically grown industrial communication networks prevent an efficient implementation of smart factory principles, especially due to a lack of semantics and the strict communication along the existing layers of the automation pyramid. This publication focuses on the development of semantic communication interfaces using the example of the digitalization of the vehicle body construction at the Audi AG. Copyright Springer-VDI-Verlag GmbH & Co. KG, Düsseldorf.
CRIS-Team Scopus Importer:2023-03-07

Sensor-guided jogging for visually impaired - Ramer, Christina; Ziegler, Christian; Reitelshöfer, Sebastian; Franke, Jörg (5th IEEE RAS/EMBS International Conference on Biomedical Robotics and Biomechatronics, 2014)
This paper introduces an approach for enabling visually impaired and blind people to practice jogging activities by 3D environment perception for course detection and collision avoidance, as well as feedback generation in an intuitive manner. Besides a system concept, first prototypic realizations, that confirm the general feasibility, are presented for this domain, which has not been addressed by research until now.
Keywords: handicapped aids; object detection; optical sensors; 3D environment perception; blind people; collision avoidance; course detection; feedback generation; optical sensors; sensor-guided jogging; visually impaired people; Belts; Cameras; Navigation; Sensors; Standards; Three-dimensional displays; Visualization

Sensor solutions for an energy-efficient and user-centered heating system - Hein, Moritz; Stöber, Ralf; Meiler, Michael; Schaller, Daniel; Zehle, Rebecca; Fischerauer, Gerhard; Bauer, Jochen; Bürner, Johannes; Franke, Jörg; Becher, Thomas; Feller, Martin; Maul, Joachim (Journal of Sensors and Sensor Systems, 2017)

Sensortechnik: Akustische Sensoren & Positions-, Weg- und Winkelmessung - Blank, Andreas (Handbuch Mensch-Roboter-Kollaboration, 2019)

Sensortechnik (Optische Sensoren, Radarsensoren, Beschleunigungs- und Drehratenmessung) - Seßner, Julian (Handbuch Mensch-Roboter-Kollaboration, 2019)

Service-based integration of modular control components in digital manufacturing platforms - Fuchs, Jonathan; Schneider, Ruwen; Oks, Sascha Julian; Franke, Jörg (2021 IEEE 19th International Conference on Industrial Informatics (INDIN), 2021)
Due to increasing complexity on the shop floor associated with the digital transformation and growing penetration of modern production environments with smart services, the operational phase of automated production facilities is gaining additional importance. The growing range of hybrid service bundles, i.e., the combination of digital services and cyber-physical production systems (CPPS), is expanding the scope of utilization and requires the application of platform-based solutions for service integration. Efficient, scalable IT infrastructures as well as technological flexibility and independence are premises for the successful implementation of these platforms. The availability of ubiquitous communication for seamless networking of all entities also plays a central role. These prerequisites enable the vertical integration of automation components on the shop floor up to the context of strategic business processes based on continuous data and information models. This paper presents an approach for integrating CPPS elements into scalable, highly available service platforms and shows how modern control approaches can be successfully linked with smart service concepts. The exemplary use case for this is a test bench for electric drive
Keywords: Smart Service; Service Bundle; Service Orchestration; Cyber-Physical Microservices; Cyber-Physical Production Systems

Servicebasierte Auftragsallokation - Scholz, Michael; Franke, Jörg (Handling, 2019)

Service quality for retail banks in the digital age - Nguyen, Huong Giang; Schäfer, Franziska; Otten, Heiner (Proceedings book of the 3rd International Conference on Quality Engineering and Management, 2018, 2018)

Service Robots for Context Recognition in Smart Environments - Dengler, Simon; Bauer, Jochen; Waldhör, Klemens; Ristok, Bruno; Franke, Jörg (dHealth 2022, 2022)
Background: A new concept for context recognition involves a smart home system, wearables, and service robots. Objectives: To find the best suited robot platform for the given use case. Methods: An assessment of available service robots based on various factors is carried out. Results: The OpenBot is best suited for the further development of this concept. Conclusion: The new concept will increase the precision and reliability in context recognitio

Seven Levels of Detail to structure use cases and interaction mechanism for the development of industrial Virtual Reality applications within the context of planning and configuration of robot-based automation solutions - Schäffer, Eike; Metzner, Maximilian; Pawlowskij, Daniel; Franke, Jörg (Procedia CIRP, 2021)
The term Virtual Reality (VR), is very well known in the consumer goods and entertainment sector. The visual presentation of the VR environment is typically achieved via stereoscopic head-mounted displays (HMD), and the interaction via a 3D position detection of HMD and additional input devices such as controllers for active user input. While the variety of applications in the entertainment industry is constantly growing and the technological possibilities become more extensive, this trend has marginally established itself in the industry. Even though powerful and affordable VR hardware is available, VR applications are often associated more with gaming than professional industrial applications. In addition, only few interaction mechanisms such as 3D viewing, moving, teleporting and rarely direct interaction capabilities are used in the most industrial VR solutions. The reason for this is often a lack of understanding and structure of use cases and the added value that VR applications and interactions create for companies and their customers. This unnecessarily limits the applicability of new VR applications for the industry. For a better structuring of VR use cases and required 3D objects for targeted user interaction, we introduce seven Levels of Detail. Along these, one VR use case setup is created, to provide examples for classical concept planning and a new knowledge-based process based on engineering Best Practices. For each, we derive adequate prototypical implemented demonstrator stations and necessary interaction mechanisms for VR development. To highlight further VR possibilities, we extend the examples by adding a second use case setup for VR planning and virtual commissioning of industrial human-robot collaboration solutions based on body and hand tracking. Hence, the contribution provides a structured compilation of potential and useful industrial VR planning use case setups and for these relevant interaction mechanisms in combination with concretely implemented examples.
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Keywords: configuration; engineering; Industrie 4.0; interaction mechanism; Level of Detail; planning; robotic; Virtual Reality; VR; VR use case

Shortening innovation cycles by employee training based on the integration of virtual validation into worker information systems - Fischer, Christian; Lusic, Mario; Bönig, Jochen; Hornfeck, Ruediger; Franke, Jörg (Procedia CIRP, 2015)
Due to rapid developments in technology, the complexity of assembly processes has increased. To meet these challenges, effectively qualified workers are necessary. A worker must have a basic education to understand new training content and be able to translate it into daily work. Also, a fast and efficient data flow from innovations within product development to training is necessary. Especially the use of three-dimensional design data has a great immersion effect for training candidates. The newly learned content is more memorable in comparison to teacher-centered education in schools. We present a solution using a worker information system for this kind of electronic learning. This system may be used even in advance of production. This concept can be extended by providing qualification or even educational content. Using multimedia data derived from computer-aided design and virtual validation, our approach for a novel training concept can be realized.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Digital Manufacturing System; Information; Learning

Simple Approach for brief RF Characterization of thin 3D printable Dielectrics - Sippel, Mark; Lomakin, Konstantin; Gold, Gerald; Reitberger, Thomas; Neermann, Simone; Helmreich, Klaus (21st IEEE Workshop on Signal and Power Integrity (SPI 2017), 2017)

Simplifying Computer Aided Ergonomics: A User-Product Interaction-Modeling Framework in CAD Based on a Taxonomy of Elementary Affordances - Wolf, Alexander; Wagner, Yvonne; Oßwald, Marius; Miehling, Jörg; Wartzack, Sandro (IISE Transactions on Occupational Ergonomics and Human Factors, 2021)
OCCUPATIONAL APPLICATIONS
CRIS-Team WoS Importer:2021-07-09

Simplifying Ergonomic Assessment for Designers: A User-Product Interaction-Modelling Framework in CAD - Wolf, Alexander; Wagner, Yvonne; Oßwald, Marius; Miehling, Jörg; Wartzack, Sandro; Wolf, Alexander; Wagner, Yvonne; Oßwald, Marius; Miehling, Jörg; Wartzack, Sandro (Proceedings of the 21st Congress of the International Ergonomics Association (IEA 2021), 2021)
Digital human models have not yet reached their full potential for proactive virtual assessment of ergonomics in engineering and industrial design. Especially the modelling of interaction between user and product often is time demanding, cumbersome, unstandardized and embedded insufficiently in the computer-aided engineering environment. On the one hand, the interaction modelling needs to be applicable for a majority of products and shall contain as much a-priori knowledge regarding human behavior as possible. On the other hand, the method needs to be appropriate for designers, without special ergonomic expertise or human behavior training. In this contribution, we present an interaction-modelling framework based on the concept of affordances, which ought to resolve these partly contradictable demands. Hence, 31 elementary affordances, describing fundamental physical interaction possibilities between human end effectors and rudimental (product) geometries, were deduced using a classification method. The elementary affordances shall serve as a medium for interaction modeling. For this purpose, we introduce an interaction modelling routine, implemented in a CAD system, which makes use of the identified elementary affordances in terms of CAD-features. Those enable designers to apply interaction possibilities directly to a CAD-model in order to define the constraints for a DHM simulatio
CRIS-Team Scopus Importer:2021-08-13
Keywords: User product interaction; Digital human models; Affordance; CAD; Interaction modelling

Simulation-aided Analysis of the Influence of Voids on the Reliability of Solder-joints for LED-Applications - Xu, Ping; Rauer, Miriam; Kaloudis, Michael; Franke, Jörg (6th Electronics System-Integration Technology Conference (ESTC), 2016)
High power LEDs have become increasingly important for industrial applications due to their long life-cycle and high energy saving potential. To achieve the maximum efficiency and lifetime, the quality and stability of the LED packages must be ensured. A critical factor is the reliability of the solder joints, especially with lead-free solder alloys because of the process-induced voids during the soldering process and consequent failure mechanisms during service. This contribution focuses on the influence of the voids on the reliability of solder joints for high-power LED applications. Concerning the long time scale for the reliability tests such as temperature shock tests (TST) or power cycling tests (PCT), finite-element-method had been considered to enable a simulation-aided analysis and to gain a better understanding of the fatigue behavior of the solder joint with different voids distributions. In the simulation, all the models are based on the real experiments with produced test assemblies with high and low voiding levels. The test assemblies were characterized before and after the reliability tests by using computer tomography (CT) in order to document the crack initiation. Based on the measured dimensions of the solder joints, 3D-models were built with different sizes and positions of voids. For the material behaviors, the Garofalo equation is implemented for calculating the creep strain and to detect the crack initiation. Various test conditions (for TST and PCT) have also been taken account of in order to reduce the deviation between reality and simulation. Finally, the simulated results of crack initiation are compared with the results of real experimental data. The Comparison shows good correlation between simulations and experimental tests with respect to failure modes such as the position of cracks. Potentials and challenges of using numerical methods are also discussed for further studies.
Keywords: Bordnetze; E|P; FEM; LEDs; reliability; solder paste; Voids

Simulation and experimental investigation for the 2D and 3D laser direct structuring process - Bachy, Bassim; Süß-Wolf, Robert; Kordaß, Timo; Franke, Jörg (International Journal of Advanced Manufacturing Technology, 2017)
The molded interconnected devices (MID) technology is vastly growing as an important innovative technology in the field of electronics production. The laser direct structuring (LDS) method is one of the most common available technologies for building up MID’s products. The current existing knowledge in industry and in research about the standards in the respective manufacturing processes and process parameters is up to now not fully comprehensive in terms of mutual influencing and dependencies on each other. This is particularly the case for the three-dimensional applications and micro products. In the present contribution, a new simulation procedures based on a three-dimensional finite element model (FEM) has been developed. The effect of each of latent heat of fusion and temperature on the material properties as well as the 3D Gaussian heat source for the laser beam has been considered in this work. The used material was a polymer plate poly ether ether ketone (PEEK). The effect of the process parameters including laser power, speed, frequency, hatching percent or overlap between the laser lines, the laser incident angle, and the focal length have been investigated in experiments and simulations. The present simulation can be used to predict, temperature distribution, maximum temperature, groove dimensions, and groove profile at different process parameters setup. The theoretical and the experimental results can show a good accordance. It can be concluded that the FEM simulation can be used efficiently for predicating, analyzing, and optimizing the 2D/3D laser parameters for the LDS process.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Finite element model; Laser direct structuring process; Laser process simulation; Molded interconnect devices

Simulation Assisted Characterization of Attenuation at Microstrip Transmission Lines fabricated by Laser Direct Structuring - Wang, Li; Lomakin, Konstantin; Job, Alexander; Süß-Wolf, Robert; Gold, Gerald; Franke, Jörg (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
This paper aims to provide a design approach to predict the attenuation of microstrip transmission lines fabricated by Laser Direct Structuring (LDS) on LDS polymer substrates. The impact of conductor and dielectric losses are separately considered in full wave simulation to evaluate the order of corresponding contribution to the total attenuation. Impact of surface roughness on signal propagation is taken into account by the Gradient Model. Simulations are compared with measurements of fabricated microstrip lines. The result also gives an estimation on the applicability of the LDS process towards radio frequency components.
CRIS-Team Scopus Importer:2021-04-02
Keywords: component; formatting; insert (key words); style; styling

Simulation-Assisted Method for Evaluating Innovative Production Technologies for Electric Traction Motors - Metzner, Maximilian; Bickel, Benjamin; Mayr, Andreas; Franke, Jörg (2018 8th International Electric Drives Production Conference (EDPC), 2018)
Keywords: Production; Traction motors; Synchronous motors; Windings; Investment; Stator cores; technology evaluation; production technology; electric motor; cost-benefit analysis; discrete event simulation

Simulation-based efficiency comparison of different mains configurations for DC grid branches for supplying production plants based on a rule-compliant design - Gutwald, Benjamin; Ngankam Ndjiemeni, Freddy; Barth, Martin; Franke, Jörg (Manufacturing Driving Circular Economy, 2022)

Simulation Based Evaluation of Energy Saving Potentials in the Field of Electric Drives Manufacturing - Spreng, Simon; Kohl, Johannes; Heisler, Paul; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production, 2015)
As the production of green products progressively influences customers’ purchase decisions, the development, assessment and controlling of energy sparing processes increasingly has to be focused. Here, one major industry sector that has to be considered is the field of electric drives manufacturing, as the main amount of industrial used energy is consumed in electric engines. Consequently, main research activities in this field focus on the development of stable processes guaranteeing high efficiency levels of the produced motors. However, aside from the products’ energy efficiency, also the energy consumptions of the actual manufacturing steps have to be improved. For this purpose, the present paper presents the main energy consumers within the assembly line of an industrial induction engine. It also explains main energy reduction measures, which were evaluated using a combined material and energy flow simulation. Hereby, the line’s base load as well as the peak load was reduce
Keywords: Energy Management; Energy Measurement; Energy Flow Simulation

Simulation-Based Optimization of the Energy Consumption in the Hardening Process for Calcium Silicate Masonry Units - Donhauser, Toni; Ehrhardt, Jens; Rackow, Tobias; Franke, Jörg; Schuderer, Peter (Energy Efficiency in Strategy of Sustainable Production, 2015)
Owing to a high cost pressure and the need for a reduction of carbon dioxide emissions for manufacturing calcium silicate masonry units (CS), the CS-industry strives to cut the energy consumption. The most energy consuming process step is the autoclaving. About 87% of the energy is required for this particular process step, where the green bodies are steam-hardened at 200°C.For reducing the energy consumption, most of the alternatives aim at optimizing the complete manufacturing process. In this paper, the focus is put on an optimized loading process for the autoclaves, in consideration of preceding and subsequent process steps. For this purpose, a simulation model is developed, where different strategies of loading are implemented and tested. This model can be used to find optimally scheduled assignments of production orders to the available autoclaves, based on the volume of each manufactured product.The analysis of the tested strategies shows, that it is possible to save up to almost 9 % of the required energy for autoclaving by an optimized assignment of the available autoclaves.
Keywords: Autoclaving; Discrete Event Simulation; Hardening Process; Optimal Assignment; Simulation-Based Optimization; Calcium Silicate Masonry Unit

Simulation-based planning and design of hybrid AC/DC energy grids for production systems: a holistic approach - Barth, Martin; Gutwald, Benjamin; Russwurm, Eva; Franke, Jörg; Lavery, Melanie; Schwanninger, Raffael; März, Martin (20. ASIM Fachtagung Simulation in Produktion und Logistik 2023, 2023)
This paper proposes a simulation-based planning concept and a simulation architecture for the design of hybrid AC/DC grids, which have the potential to significantly contribute to the energy transition. The paper discusses the lack of knowledge in the market for the design of these grids, and presents a simulation approach to efficiently assemble hybrid networks and analyse them based on an electrical simulation. The authors also address the need to include process-specific characteristics in the planning and analysis of the electrical network, which is why common simulation tools for production processes are included in the approach. This allows economic, ecological, safety-relevant and technical aspects to be integrated into the planning process. The proposed concept is further discussed and planned for validation on the basis of a demonstrator currently under construction.
Keywords: Produktion; Logistik; Simulation

Simulation-Based Robot Placement Using a Data Farming Approach - Lechler, Tobias; Krem, Georg; Metzner, Maximilian; Sjarov, Martin; Franke, Jörg (Production at the leading edge of technology, 2020)

Simulationbasierte Optimierung von Fabrikabläufen: Implementierung und Test eines Algorithmus zur ereignisbasierten Regelung der Materialflüsse - Donhauser, Toni; Baier, Lukas; Ebersbach, Tobias; Franke, Jörg; Schuderer, Peter (wt Werkstattstechnik - Online, 2018)
Die Kalksandsteinherstellung weist aufgrund prozesstechnisch und zeitlich divergierender Teilprozesse einen hohen Planungs- und Steuerungsaufwand auf. Durch Anwendung eines simulationsgestützten Optimierungsverfahrens kann diese Komplexität bewältigt werden. Um bei hoher Lösungsqualität eine Laufzeit zu erreichen, die einen operativen Einsatz des Verfahrens gestattet, wird auf Basis einer vorangegangenen Studie ein Dekompositionsansatz implementiert und dessen Eignung durch Testläufe validiert.
Keywords: Discrete Event Simulation; Kalksandstein; Simulation-based Optimization; simulationsgestützte Optimierung