Influence on the optical performance of droplets and enclosures in printed polymer optical waveguides - Backhaus, Carsten; Förner, Johannes; Wienke, Alexander; Hoffmann, Gerd-Albert; Eiche, Yannic; Lorenz, Lukas; Kaierle, Stefan; Overmeyer, Ludger; Franke, Jörg; Bock, Karlheinz; Lindlein, Norbert (Physics and Simulation of Optoelectronic Devices XXIX, 2021)
Printing polymer optical waveguides by means of combined printing processes has proven to be a challenging but effective way of producing waveguides with a loss less than 0.3dB/cm. In order to evaluate the optical performance of the produced waveguides, optical simulations have been carried out. In this work we show the influence on the optical performance by simulating droplets and enclosures in multimode waveguides with a proprietary raytracing algorithm. Critical waveguide parameters such as width and height variation will be evaluated. Finally, experimentally achieved optical performance is presented and compared with the simulation resul
Keywords: Raytracing; Polymer Optical Waveguides; Aerosol Jet Printing; Optical Simulation; Waveguide Quality Analysis; Signal Attenuation; Waveguides; 3D Printing

Influences of Crack Initiation in Conductor Tracks on Three-Dimensional Thermoplastic Substrates - Kuhn, Thomas; Franke, Jörg (Proceedings of the SMTA Pan Pacific Microelectronics Symposium, 2017)
Advanced mechatronic products are distinguished by a high functional density in miniaturized design. Due to the versatile possibilities to apply circuitry and functional structures directly on spatial substrates, the MID technology (Molded Interconnect Devices / Mechatronic Integrated Devices) provides enormous potential for multi-functional mechatronic solutions in various areas of application. The laser direct structuring process (LDS), as the most widely used production method in the field of MID, has become well established in the market in recent years. This process is based on a structured exposure and activation of a special additive embedded in an injection-molded thermoplastic substrate by the use of a laser beam. The resulting metallic seeds and micro-rough structures on the substrate surface enable a subsequent selective metallization in an external electroless metallization process. A decisive factor for the quality and reliability of LDS-MID is the crack tendency of the metallized conductor tracks. Cracks in the metallization primarily result from mechanical and thermomechanical stresses of the device caused by environmental influences during use as well as by stressfull conditions during production processes. The thermomechanical stress of MID is particularly effected by the differences in thermal expansion of the thermoplastic substrate materials and the metallization. The paper presents results of comprehensive investigations on the crack initiation in LDS conductor tracks. The influences of specific properties caused by geometric characteristics and injection-molding-related conditions on the initiation of cracks were investigated using specially designed three-dimensional specimens. These specimens consider MID-typical surfaces, such as concave and convex shapes, edges, weld lines, or ejector markings. For the investigations, specimens were produced in a standard variant with typical production parameters as well as in a variant with reduced metallization roughness using less laser power and a CO2 snow-jet cleaning after the structuring process. The cracking behaviour of the conductor tracks was evaluated under stress conditions through temperature shock (1000 cycles, -40 °C / 125 °C) and damp heat tests (1000 hours, 85 °C / 85 % rel. humidity) by monitoring the electrical resistance of applied meander-shaped test circuits. An online measurement during the tests enables the detection of cracks from the recorded resistance profiles and provides information on the time of crack formation and the prevailing conditions. Furthermore, damaging effects, which occur only temporarily during the periods of stress, can be detected. The results of the investigations clearly show significant influences on the crack tendency of LDS circuit tracks under stressfull environmental conditions and thus provide helpful hints to improve the reliability of LDS-MID. A considerable increased crack susceptibility can be recognized at specimens exposed to a reflow soldering process prior to the environmental tests. Regarding the properties of the circuit tracks, layers with reduced roughness clearly show a lower risk of cracking than layers with a higher roughness. A further decisive factor concerning the crack tendency is the substrate shape. Conductor tracks on convex surfaces increase the risk of cracking remarkably, whereas concave circuit tracks reduce the risk of failures.
Keywords: E|P; EP; MID; Zuverlässigkeit

Influences of joining process parameters on stator and rotor cores for electric drives - Ziegler, Marco; Biburger, Michael; Kühl, Alexander; Franke, Jörg (2019 16th Conference on Electrical Machines, Drives and Power Systems, ELMA 2019 - Proceedings, 2019)
Due to the rising demand for high-efficiency electric drives, the requirements for production processes are also increasing. The process steps have a significant effect on product quality and efficiency of the electric machine. In this paper, the joining processes for stator and rotor lamination stacks i. e., interlocking, laser welding, bonding and bonding varnish are compared in a holistic evaluation process. For this purpose, practical joining tests with varying process parameters on basis of a toroidal core are carried out. In this context, the process behavior and energy demand during manufacturing are evaluated. Mechanical and electromagnetic tests are used to determine the influence of the joining parameters on product quality and electromagnetic losses. The investigations were intended to support the later development of new complex processes for electric drives.
CRIS-Team Scopus Importer:2019-08-20
Keywords: Electromagnetic losses; Joining processes; Mechanical tests; Stator and rotor cores

Influences of Manufacturing Sequences for the Application of Printed Electronics on Aircraft Interior Components - Ischdonat, Nils; Dreyer, Christian; Gräf, Daniel; Franke, Jörg; Horber, Johannes; Hedges, Martin (2018 13th International Congress Molded Interconnect Devices (MID), 2018)
Keywords: aerosols; aerospace components; aircraft; aircraft manufacture; assembling; jets; printed circuits; printing technologies; aerosol-jet; final assembly line; piezo-jet; installation process; weight reduction; cabin lining components; cabin interiors; FAL; robotics; digitalization; aircraft interior components; manufacturing time; smarter cabin interior components; printed electronics; Printed circuits; Printing; Ink; Conductivity; Substrates; Manufacturing; Curing; Sandwich Construction; Printed Electronics Manufacturing Process; Aerosol-Jet; Piezo-Jet; SilverNanoparticle Ink; Functional Integration; Scanning Electron Microscope

Influences of process parameters on rare earth magnets produced by laser beam melting - Urban, Nikolaus; Huber, Florian; Franke, Jörg (Proceedings of the 2017 7th International Electric Drives Production Conference (EDPC), 2017)

Influencing Factors for the Ultrasonic Compacting Process of Insulated Litz Wires for Electric Drives - Seefried, Johannes; Riedel, Andreas; Lohbauer, Andreas; Baessler, Hendrik; Kühl, Alexander; Franke, Jörg (30th International Conference on Electrical Contacts, ICEC 2020 - Proceedings, 2021)
The increasing demand for new electric drive concepts in the automotive sector leads to innovations in the development and production of these drives. Due to the demand for steadily higher drive speeds, litz wires, also called stranded wires, offer various advantages in terms of loss reduction. These losses include current displacement due to the skin- and proximity effect in the wire at higher frequencies. However, these litz wires complicate the process step of contacting the winding ends. For example, during this contacting process it is necessary to connect a high number of individual wires electrically conductively and mechanically with each other. However, these individual wires must be stripped simultaneously during the process. One possibility to implement this process step is the ultrasonic compaction process. By applying and damping ultrasonic oscillations, the individual wires can be thermally stripped and also welded together. However, a wide range of influencing parameters must be validated for this process. These include relevant process parameters as well as properties of the litz wires used. Among other things, the properties can be divided into the type of insulation, the number of individual wires and their diameter. Within this publication, the essential process parameters are identified and evaluated in terms of the quality of the compaction by using suitable methods for measuring the node resistance.
CRIS-Team Scopus Importer:2023-03-07

Influential parameters in the development of Transient Liquid Phase Soldering (TLPS) as a new interconnect system for high power lighting applications - Syed Khaja, Aarief Hussain; Franke, Jörg (IEEE CPMT Symposium Japan 2015, ICSJ 2015, 2015)
This paper gives an overview on Transient Liquid-Phase Soldering (TLPS) as a new interconnect system for lighting components at package as well as chip level, 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 with control of temperature, time and pressure has been investigated in production perspective. The samples processed under optimized over-pressure reflow soldering along with realization of thin solder layers down to less than 15 μm are demonstrated. As a result, TLPS joints with < 3 % voids with fully grown Sn-Cu intermetallic phases have been realized. Formations of intermetallic phase (IMP) with changes in soldering profile, solder paste height, chip metallization and substrate roughness are discussed.
Keywords: Board-Level Integration; Diffusion Soldering; Intermetallics; LEDs; Materials for Packaging

Information Asymmetry in Business-to-Business Negotiations: A Game Theoretical Approach to Support Purchasing Decisions with Suppliers - Bodendorf, Frank; Hollweck, Barbara; Franke, Jörg (Group Decision and Negotiation, 2022)
The digital transformation confronts purchasing and supply management (PSM) with numerous new challenges, such as digital procurement objects and the information asymmetry between buyers and suppliers. Existing approaches contributing to PSM research (e. g., the selection of suppliers or the calculation of equilibrium prices) have in common that information regarding suppliers (e. g., production costs) must be well-known. However, this information is rarely accessible to purchasers due to the existing information asymmetry. This problem is addressed by a game-theoretical model based on a Stackelberg game to assist PSM in dealing with the information advantage of software suppliers. The applicability in practice is evaluated by a real-world case study from the automotive industry. The results show that the presented model can support decision-making in purchasing by a qualitative analysis of profit scenarios for different negotiation strategies. The model contributes to dismantling the information asymmetry and provides a basis for determining negotiation prices, also for digital procurement objects. This research motivates both supply and purchase managers to jointly optimize their product costs and thus increase their competitiveness on the market.
CRIS-Team WoS Importer:2022-06-24
Keywords: Game theory; Information asymmetry; Decision support; Negotiation; Supply management; Cost management

Infrared laser based contacting of bar-wound windings in the field of electric drives production - Gläßel, Tobias; Baat, Florian; Schwinghammer, Daniel; Seefried, Johannes; Kühl, Alexander; Franke, Jörg (Procedia CIRP, Volume 74, 2018)
Driven by electric mobility innovative winding methods increasing the copper fill ratio and thus the power density of electrical drives gain in importance. Compared to conventional windings, bar-wound windings based on rectangular cross sections besides optimized copper fill ratios also offer advantages in terms of automated production. Because of the high number of joints necessary for the manufacturing of the winding, contacting efforts increase significantly wherefore the process of laser welding, due to its short process times and high reproducibility shows potentials to realize the process step. This paper examines the most important interactions within the process of laser welding of insulated copper wires with rectangular cross sections in the context of electric drives production. Besides workpiece specific factors, the focus is set on process parameters, beam guidance strategies and specific quality requirements. For this purpose, a parameter study based on design of experiments is executed in which suitable measuring technologies are used to quantify the properties of the samples. <br
Keywords: laser beam welding; infrared lasers; insulated copper conductors; hairpin windings; electrical contacts

Inline calibration method for robot supported process tasks with high accuracy requirements - Buschhaus, Arnd; Wagner, Maximilian; Franke, Jörg (2017 IEEE International Conference on Advanced Intelligent Mechatronics (AIM), 2017)

In-line Measurement Techniques of Resin-based Insulation Processes for Wireless Power Transfer Systems - Kneidl, Maximilian; Benke, Daniel; Masuch, Michael; Kühl, Alexander; Franke, Jörg (2021 IEEE Conference on Electrical Insulation and Dielectric Phenomena (CEIDP), 2021)
The increasing demand for electric mobility is continuously generating innovations in the development and production of electrical machines such as wireless power transfer (WPT) systems. Therefore, new insulation resins with different filler types are investigated in detail to prevent electrical breakdowns and to increase the thermal conductivity of the whole insulation system. In contrast to the development and optimization of new materials, the application technology, process control and testing still remains largely unchanged. As a result, the transfer of the optimized material properties of new insulation resins to the specific component properties is restricted. In the worst case, this leads to an inappropriate processability of the resin and subsequently to the failure of the electrical machine. Furthermore, end-of-line tests only allow a qualification of the final insulation system after impregnation and curing. Thus, defective components can only be identified and discarded or repaired at the end of the process chain, which causes additional costs in production. The aim presented in this work is to identify and measure the dielectric properties of the insulation material along the encapsulation process of a coil structure for WPT systems, to derive information about the overall quality of the insulation system. Therefore, a test setup for qualifying the insulation system capability during the encapsulation process will be elaborated. The results of the in-line measurements are then validated with partial discharge measurements and micrographs of the conductor structur

In-Line strategies and methods to reduce balancing efforts within rotor production for electric drives - Hofmann, Benjamin; Masuch, Michael; Frey, Philipp; Franke, Jörg; Merklein, Marion (6th International Electric Drives Production Conference (EDPC), 2016)
Within a research project focussing the optimization of the entire process chain of rotor production, balancing is identified as one of the processes with a high potential for innovation. As most research efforts concentrate on the additive or subtractive process itself, the presented paper follows a different approach concentrating on the impact of process steps prior to rotor assembly and the actual balancing operation. Within current production processes, weighing is almost exclusively performed as an end-of–line process to take the entire rotor assembly into account. However, concerning the production of drives with permanent magnets, particularly those with magnets integrated into the lamination stack (IPM-Drives), production steps leading to the rotor assembly already deliver prefabricated lamination modules that can be evaluated regarding their imbalance. By determining the imbalance of those modules and a varying rotational combination of a number of modules being needed to form a complete rotor assembly, balancing efforts are considered to be reduced significantly; resulting in a lighter rotor assembly due to thinner end caps on the rotor. The presented Paper describes methods and strategies to evaluate the imbalance of single lamination stacks and their preferred orientation prior to their assembly onto the rotor shaft. Depending on the rotor topology (pole number, magnet count), restrictions regarding free rotation have to be considered. Additionally, known methods for balancing in single and double layers have to be practically analysed and compared for the balancing operation in focus. Using pre-stacked laminations, the balancing operation is validated in practice to determine actual effects on the imbalance of a complete lamination stack. Using different combinations for aggregating single packages, the imbalance can be reduced by up to 30%.<br
Keywords: balancing; rotor; electric drives

Innovationen für die Elektromotorenproduktion von morgen: Von neuen Prozesstechnologien, Automatisierungslösungen bis hin zu Industrie 4.0-Ansätzen - Mayr, Andreas; Masuch, Michael; Kühl, Alexander (Automobiltechnologie in Bayern + e-Car, 2019)

Innovations for the electric motor production of tomorrow: From new process technologies, automation solutions through to Industry 4.0 approaches - Mayr, Andreas; Masuch, Michael; Kühl, Alexander (Automobiltechnologie in Bayern + e-Car, 2019)

Innovative and energy-efficient insulation technology for the production of electric drives - Hofmann, Benjamin; Spreng, Simon; Franke, Jörg; Maryniak, Bernd (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
Resin applications have always been found within the production of electric drives. Replacing natural materials like tar and rubber, industrial produced polymers quickly spread amongst all major components and manufacturing steps of electric machines. Today, thermosetting resins are mainly used within the disciplines of insulation and fixation of materials, manifesting in wire enamels, impregnation varnishes, potting resins and thermally curing adhesives. As broad as their manifestations are the challenges around these products. Thermal curing generally uses an excessive amount of energy when being conducted by oven heating or infrared radiation. Alternative and particularly energy-efficient technologies are available, but have yet to be investigated from a scientific perspective. Within the research project ESolation, the FAPS institute has aimed to investigate inductive heating technology as an energy-saving method for thermosetting resin and powder coat curing to create insulating layers within an automated and flexible production of electric drives. Saving potential in the context of electrical sheet laminations has shown to be as high as up to 95% of electrical energy. In order to determine the value of this technology, simulative as well as empiric investigations have to be made to create a better understanding of how inductive heating of sheet lamination works and to determine feasibility and integration into current production processes.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Impregnation; Insulation; Resin

Innovative Approach of efficient High Humidity and High Temperature Reverse Bias Testing as significant Qualification Method for Power Electronic Modules - Müller, Martin; Franke, Jörg (2018 IEEE 20TH ELECTRONICS PACKAGING TECHNOLOGY CONFERENCE (EPTC), 2018)
CRIS-Team WoS Importer:2019-04-12

Innovative Approach of efficient low-temperature silver sintering on an industrial series scale for simultaneous die top and bottom level interconnections of power electronic applications - Müller, Martin; Franke, Jörg (2019 IEEE 21st Electronics Packaging Technology Conference, EPTC 2019, 2019)
In recent years, the number of power electronic assemblies has increased significantly both in products and machines for the end user and in products and machines for industry. Above all, however, power electronics is becoming more and more important in drive technology and the generation of renewable energies. Power electronic modules, such as inverters and rectifiers or DC converters, are required to provide more and more power in the advancing field of electromobility, while the installation space is constantly being reduced. At the same time, however, these assemblies must have the longest possible and most reliable lifetime. Previous power electronic modules have a maximum junction temperature of 150 °C due to the materials used in assembly and connection technology. New types of wide band gap semiconductors, however, already offer the possibility of enabling junction temperatures of 200 °C and above. The aim of the investigations in this paper is to qualify a sintering process that is suitable for efficient series production for an all-in-one joining process in assembly and interconnection technology. By replacing the solder layer with a silver sinter paste, operation at junction temperatures significantly above 150 °C is possible. However, if the maximum junction temperature is maintained at the current level of 150 °C, higher reliability and longer lifetime of the power electronic modules are expected. In active power cycling tests, the reliability of the demonstrators produced in the series sintering process is compared with the service life of soldered reference samples.
CRIS-Team Scopus Importer:2021-04-20

Innovative Assembly of Stators using Ambidextrous Kinematics - Kühl, Alexander; Franke, Jörg (WCECS 2015 - World Congress on Engineering and Computer Science 2015, 2015)
Keywords: E|DRIVE; Motor; Electric Motor; Robot

Innovative control of assembly systems and lines - Krueger, J.; Wang, Lihui; Verl, Alexander; Bauernhansl, Thomas; Carpanzano, Emanuele; Makris, S.; Fleischer, Jurgen; Reinhart, G.; Franke, Jörg; Pellegrinelli, S. (CIRP Annals - Manufacturing Technology, 2017)
The increasing demand for flexibility and reconfigurability of assembly lines generates new challenges for the control of these lines and their subsystems, such as robots, grippers, conveyors or automated guided vehicles. Also new requirements for their interaction between each other and the environment as well as with humans arise. On the other hand the rapid change of information and communication technology opens new potentials for innovative control. Due to the high degree of interconnection between controllers, actuators and sensors, the classical automation pyramid is replaced by networked structures with a higher degree of flexibility, but also higher complexity. This trend is supported by the ability to collect and process data within cloud environments, the rapid increase of computational power of decentralized and embedded controllers and the high potential of machine learning for automation. This keynote gives an overview of innovative approaches in ICT and robotics for flexible control and automation of assembly lines and systems.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Cloud technology; Control; Robotics

Innovative developments for automated assembly and fixation of integrated permanent magnets in rotors of synchronous machines - Meyer, Alexander Wilhelm; Mahr, Alexander; Hofmann, Benjamin; Masuch, Michael; Franke, Jörg (5th International Conference on Electric Drives Production, EDPC 2015, 2015)
Automation in the field of magnet handling and rotor assembly for permanent magnet synchronous motors is growing constantly, due to rising market share of high output motors. In the past, especially at the institute FAPS, large efforts have been made to reduce the amount of manual processes for maintaining market expansion and the increase of efficiency of the electric machine. Current research work has the aim of increasing the grade of automation even for large numbers of variants with low investment. In this paper two different demonstrators one for handling and one for the fixation of magnetized high coercive magnets are presented. The handling device inserts magnets of different dimensions in cavities vertically. For demonstrating an integrated fixation process an existing magnet assembly unit has been modified to enhanced functionality. Both devices offer fully automated operation ability within a wide portfolio of different rotor types and magnet dimensions.

Innovative developments for automated magnet handling and bonding of rare earth magnets - Franke, Jörg; Tremel, Jan; Kühl, Alexander (2011 IEEE International Symposium on Assembly and Manufacturing, ISAM 2011, 2011)
Keywords: Assembly; Handling; Bonding; Permanent Magnet

Innovative Flexible Heating System by the Use of Additive Plasma Coating Technology: Heating Where Heat Is Needed by Additive Metallization of Furniture and Walls - Braun, Thomas; Bürner, Johannes; Michl, Markus; Schaller, Lukas; Böhm, Ralf; Franke, Jörg (Proceedings of the 4th International Conference on Smart Energy Grid Engineering (SEGE), 2016)

Innovative Kontaktierungstechnologien im Elektromaschinenbau Entwicklung, Qualifizierung und Optimierung - Gläßel, Tobias; Spreng, Simon; Spahr, Michael; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2016)
Im sich dynamisch entwickelnden Feld der elektrischen Antriebstechnik stellen neue, von der Automobilindustrie getriebene Motortopologien sowie die Forderung nach serienflexiblen Prozessen die zentralen Treiber zur Entwicklung innovativer Kontaktierungsverfahren dar. Die Arbeitsgruppe Kontaktierungstechnologien begegnet diesem Spannungsfeld mit einem multidimensionalen Ansatz, der aus der Weiterentwicklung bestehender und aus der Erforschung neuartiger Kontaktierungslösungen besteht.
Keywords: Kontaktierungstechnologien; elektrische Maschinen

Innovative methods for automated assembly and fixation of permanent magnets in electrical machines - Franke, Jörg; Hofmann, Benjamin; Tremel, Jan; Meyer, Alexander Wilhelm (Procedia CIRP, 2015)
Over the years, the production of electric machines has spread into different designs, creating complex variations in topologies and structure. Based upon a recently completed research project, the handling, assembly and fixation of permanent magnet components for electrical machines containing internal permanent magnets (IPM) is investigated. An assembly and fixation process is presented both of which are economical in terms of use of adhesives and variant flexibility. The developed solution is based on a SCARA-Robot with an attached device that is capable of both separating and assembling the permanent magnet material. The elimination of an off-site magnet separation and a continuous feed of magnets significantly reduces the cycle time for a single rotor. The flexibility of the SCARA concept ensures its application in a broad field of different rotor sizes. Recent solutions for affixing the IPM material are often based on a complete submersion of magnets into resin material. An alternative approach for adhesive application has been developed and integrated into the assembly process that reduces the overall need for adhesive material by over 80%.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Fixation; Handling

Innovative needle winding method using curved wire guide in order to significantly increase the copper fill factor - Stenzel, P.; Dollinger, P.; Richnow, J.; Franke, Jörg (2014 17th International Conference on Electrical Machines and Systems, ICEMS 2014, 2014)
The increase of the copper fill factor is an essential production goal in stator winding technology in order to increase the degree of efficiency and the power density of electrical machines. Orthocyclic winding patterns allow the highest packing density. Currently for round-wire-windings there are only systems available on the market that facilitate random windings, which leads to a decrease of the fill factor. Therefore this paper introduces a concept allowing high fill factors for distributed windings by using the needle winding technology.
CRIS-Team Scopus Importer:2023-03-07

Innovative processes and systems for the automated manufacture, assembly and test of magnetic components for electric motors - Franke, Jörg; Dobroschke, Andreas; Tremel, Jan; Kühl, Alexander (1st International Electric Drives Production Conference, EDPC-2011, 2011)
Keywords: Coil Winding; Automated Assembly; Robotic Assembly; Permanent Magnet Assembly

Innovative, release agent-reduced manufacturing concepts for the manual series production of complex foam parts - Heisler, Paul; Gick, Sascha; Franke, Jörg (4th International Conference on Control, Automation and Robotics (ICCAR), 2018)

Innovative signal and power connection solutions for alternative powertrain concepts - Fröhlig, Simon; Piechulek, Niklas; Friedlein, Matthias; Süß-Wolf, Robert; Schmidt, Lorenz; Kuhn, Marlene; Wang, Li; Hefner, Florian; Heisler, Paul; Fröhlich, Jan; Meiners, Moritz; Franke, Jörg (2020 10th International Electric Drives Production Conference (EDPC), 2020)
Since the automotive wiring harness interconnects all electrical components in a vehicle, it also must adapt to all componential, mechanical, and electrical architecture changes. For this reason, almost all trends that affect the vehicle in general also affect the wiring system. This paper describes the current situation, analyses the most important trends in the automotive industry, and discusses their effects on the wiring system. In particular, the focus is on the current megatrend of electromobility and the associated electrification of the powertrain. In addition to the integration of autonomous driving functions and Car-To-X- Communication, the electrification adds new requirements and tasks for the wire harness. In this context, a holistic approach is taken to combine various fields of research such as automation solutions, computer-aided technologies, functional integration, as well as reliability models to offer a solution for the challenges caused by current automotive trends.<br
Keywords: electromobility; wiring harness; vehicle electrical system; signal and power connection; alternative powertrain

Innovative Solutions for the Covering Process in the Manufacturing of Wire Harnesses to Increase the Automation Degree - Heisler, Paul; Kuhn, Marlene; Süß-Wolf, Robert; Franke, Jörg (2020 IEEE 11th International Conference on Mechanical and Intelligent Manufacturing Technologies (ICMIMT), 2020)

Innovative trennmittelarme Fertigungskonzepte für die Schaumteilherstellung in der Serienfertigung - Heisler, Paul; Gick, Sascha; Franke, Jörg (Werkstoffe in der Fertigung, 2019)

In-situ identification of material batches using machine learning for machining operations - Lutz, Benjamin; Kißkalt, Dominik; Mayr, Andreas; Regulin, Daniel; Pantano, Matteo; Franke, Jörg (Journal of Intelligent Manufacturing, 2020)
In subtractive manufacturing, differences in machinability among batches of the same material can be observed. Ignoring these deviations can potentially reduce product quality and increase manufacturing costs. To consider the influence of the material batch in process optimization models, the batch needs to be efficiently identified. Thus, a smart service is proposed for in-situ material batch identification. This service is driven by a supervised machine learning model, which analyzes the signals of the machine's control, especially torque data, for batch classification. The proposed approach is validated by cutting experiments with five different batches of the same specified material at various cutting conditions. Using this data, multiple classification models are trained and optimized. It is shown that the investigated batches can be correctly identified with close to 90% prediction accuracy using machine learning. Out of all the investigated algorithms, the best results are achieved using a Support Vector Machine with 89.0% prediction accuracy for individual batches and 98.9% while combining batches of similar machinability.
CRIS-Team WoS Importer:2021-01-15

Integrated Energy-Controlling in Industrial Value Chains - Rackow, Tobias; Donhauser, Toni; Schuderer, Peter; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production, 2015)
The energy efficient production of goods can only be used as a unique selling proposition, if reliable values for the energy consumption, caused by production and transportation, are determinable. Furthermore, the customer must be able to compare these values for different products. Using a consistent and standardized methodology for calculating these values along the value chain, this comparability can be achieved. Providing this information, as potentially required by the end customer or by law, the penetration of this methodology could be achieved, while obviously the comparably more energy efficiently produced goods would be more attractive for the (end) customer. Consequently, an incentive system would emerge, which motivates the companies to improve their energy efficiency throughout the complete value chain. The following paper presents the above-mentioned methodology along with a unified scheme for allocating the energy consumption of the production to products.
Keywords: Value Chain; Energy Management; Energy Efficiency; Energy Controlling

Integrating digitization technologies into resource efficiency driven industrial learning environments - Böhner, Johannes; Scholz, Michael; Franke, Jörg; Sauer, Alexander (Procedia Manufacturing - Volume 23, 2018)

Integrating Intralogistics into Resource Efficiency Oriented Learning Factories - Scholz, Michael; Kreitlein, Sven; Lehmann, Christian; Böhner, Johannes; Franke, Jörg; Steinhilper, Rolf (6th CIRP Conference on Learning Factories, CLF 2016, 2016)
Establishing lean and green learning factories is a practical approach to meet rising resource efficiency requirements in industrial manufacturing. Besides lean aspects, the impact of increasing flexibility in intralogistics on energy consumption needs to be quantified and transferred to industry decision makers via suitable learning scenarios to deepen the understanding of energy-related dependencies of various transport technologies. This paper presents an approach for a systematic identification and implementation of lean and resource efficiency potentials focusing on automated guided vehicles. Therefore, energy efficiency of alternative assets is measured, simulated and characterized by using Energy Performance Indicators.
Keywords: Energy Efficiency; Energy Performance Indicators; Flexibility and Transparency in Manufacturing Education; Learning Factory; Resource Efficiency

Integrating optical 3D measurement techniques in pipe bending: a model-based approach minimising waste by deriving real functional design behaviour - Katona, Sebastian; Lušić, Mario; Koch, Michael; Wartzack, Sandro (Procedia CIRP, 2016)
Due to springback, deviations compared to the designed ideal modal occur during pipe bending processes. With quality control gauges no quantitative statements can be made regarding the process stability. The components are either good or bad and no production trends can be determined. This leads to high scrap rates and in addition, the real performance of the produced components may differ from the target behaviour of the initially designed CAD model. As addressed within this contribution, with integrating optical 3D measuring systems into the bending process, the actual state can be detected continuously. This enables to give feedback to the bending device for automatically readjust of bending parameters and thus prevent producing defective components. Moreover, the digitalisation of the actual contour allows a parametric correction of the designed CAD model, whereby the functional behaviour can be closer to reality within simulation models.
Keywords: In-process measurement; bending; springback; computer aided design (CAD); simulation; real function design behaviour

Integrating Workers’ Feedback into Continuous Information Flows: Enabling Lean Quality Assurance by Worker Information Systems - Fischer, Christian; Lusic, Mario; Faltus, Florian; Hornfeck, Rüdiger; Franke, Jörg (WGP Congress 2016, 2016)
Worker information systems provide the right information at the right time in a lean way. In this paper, the need for an integrated feedback system with formalised text parts is exposed. To meet the disadvantages of a lack of feedback, two important points are identified: involving of workers and guaranteeing a high information quality. Several approaches show that workers have to be included into an early stage of product development process to improve product details and especially assembly scenarios. Also, workers get an idea of their contribution to a zero-waste production. If more information is created, the quality gets more important. It is explained what quality criteria should be considered. Technical realisations for a feedback system close this paper.
Keywords: Assembly; Feedback System; Information

Integration eines Multi-Agenten-Systems in eine Ereignisdiskrete Materialflusssimulation - Scholz, Michael; Donhauser, Toni; Franke, Jörg (Tagungsband Workshop 2018 ASIM/GI-Fachgruppen, 2018)

Integration maschineller Lernverfahren in eine Materialflusssimulation zur Verhaltensabstraktion und -vorhersage komplexer Fertigungssysteme - Donhauser, Toni; Kißkalt, Dominik; Mayr, Andreas; Scholz, Michael; Schuderer, Peter; Franke, Jörg (ASIM 2019 - Simulation in Produktion und Logistik, 2019)

Integration of electric vehicles in time-flexible charging processes through contracting models - Fehrle, Adrian; Funk, Felix; Teske, Franz; Dorscht, Felix; Franke, Jörg (2021 11th International Electric Drives Production Conference (EDPC), 2021)
The increasing popularity of electric vehicles (EVs) is leading to major challenges for utilities. The existing low-voltage grid will not be able to support the growing number of simultaneously charging vehicles and would therefore have to be expanded at high cost. In addition, these high charging phases lead to extreme demand peaks, which the utilities must meet by purchasing energy on the electricity spot market at expensive quarter-hourly rates. Through flexible charging processes controlled by the utilities, these costs could be significantly reduced. Similarly, grid utilization can be equalized by shifting the charging phases while parking to more beneficial electricity price periods. Nevertheless, it is guaranteed that there will be no comfort restrictions for the EV owner. To make this possible, EV owners have to enable the utilities to include their vehicles in the flexible charging process. In this paper, we present a contracting model for EVs, in which costumers do not buy the vehicle but lease it from the local utility instead. Reduced leasing rates incentivize end costumers to integrate their EV into the charging process optimization of the utility. Our findings show that this contracting model leads to significant cost savings for all parties involved.
Keywords: Adaptation models; Low voltage; Costs; Smoothing methods; Process control; Tariffs; Production; electric vehicles; contracting; utilities; power grids; flexibilities

Integration of electric vehicles into low-voltage grids with limited capacity using a smart market - Teske, Franz; Funk, Felix; Fehrle, Adrian; Franke, Jörg (2021 11th International Electric Drives Production Conference (EDPC), 2021)
In the next few years, many electric vehicles (EV s) will need to be integrated into low-voltage (LV) grids, which, according to current paradigms, will result in high grid expansion requirements and enormous costs. Therefore, it is planned to reduce the grid expansion in the distribution grid and to implement smart solutions to manage the locally limited transmission capacity. It must be ensured that no overloads of transformers and power lines as well as undervoltage problems occur. In this paper, the implementation of a smart market that efficiently distributes the limited infrastructure is proposed. This is accomplished by calculating the available grid capacity based on the grid topology and other local supply and demand. The remaining capacity is distributed through a market mechanism. Based on a typical grid setup, it can be shown that the presented concept utilizes the existing power grid more efficiently than time-based control and time-limited prohibitions of charging processes. Through the market mechanism, the individual charging requirements can be considered and thus an improved temporal distribution of the charging quantities can be achieved.
Keywords: Low voltage; Costs; Supply and demand; Switched mode power supplies; Tariffs; Electric vehicles; Transformers; smart market; power distribution planning; low voltage grid; power grids

Integration of polymer optical waveguides by using flexographic and aerosol jet printing - Reitberger, Thomas; Franke, Jörg; Hoffmann, Gerd-Albert; Overmeyer, Ludger; Lorenz, Lukas; Wolter, Klaus-Jürgen (12th International Congress on Molded Interconnect Devices, MID 2016, 2016)
Keywords: Aerosol Jet Printing; Conditioning; Flexographic Printing; Optical; Printing

Integration of Semi-Automated Routing Algorithms for Spatial Circuit Carriers into Computer-Aided Design Tools - Zeitler, Jochen Tobias; Fischer, Christian; Goetze, Bernhard; Franke, Jörg (Electronics Circuit World Convention 13 (ECWC 13), 2014)
Though the market for 3D Molded Interconnect Device applications increases fast, the engineering process of these mechatronic assemblies still lag behind. The integration of electronic and mechanical design on mechatronic assemblies with complex spatial surfaces is a challenging task in the development process. This paper describes a method to create a MID specific product model that fulfills both requirements. This is on the one side the electrical design and on the other side the mechanical design. Both are considering design- and manufacturing rules, respectively keep-out areas. This product model is tied to two different mechanical computer-aided design systems, AutoCAD Inventor on the one side and Siemens NX on the other side. Furthermore the concept to flatten the 3D-circuitry, suitable for the surfaces of volume bodies, to ease 3D routing, will be discussed in this paper.
Keywords: MID; Design; CAD

Intelligent cost estimation by machine learning in supply management: A structured literature review - Bodendorf, Frank; Merkl, Philipp; Franke, Jörg (Computers & Industrial Engineering, 2021)
In the automotive industry, cost estimation of components to be purchased plays an important role for price negotiations with suppliers and, therefore, for cost control within the supply chain. While traditional bottom-up cost estimation is a very time consuming and know-how intensive process, intelligent machine learning methods have the potential to significantly reduce the effort in the cost estimation process. In this paper, a literature review on intelligent cost estimation methods for parts to be procured in the manufacturing industry is carried out by text mining. Following the results of this literature review, building blocks for an intelligent cost estimation system are outlined that comprise cost estimation methods, dimensionality reduction methods, methods for multi-level cost estimation, and methods for interpreting the results of the cost analysis. Regarding cost estimation methods, Artificial Neural Networks and Support Vector Machines outperform established linear regression algorithms. Dimensionality reduction methods like Correlation Analysis or Principal Component Analysis are rarely studied. Nevertheless, they contribute a lot to the reduction of expensively provided input parameters for cost estimation. Methods for multi-level cost estimation, that support cost prediction of parts and assemblies following the construction plan of a vehicle, and methods for interpretation of intelligent cost analytics cannot be found at all in literature. Consequently, in this paper corresponding approaches are derived from the areas of Multitask Learning and Explainable Machine Learning. Finally, a combination of methods considered most suitable for predictive analytics to estimate procurement costs is presented.
Created from Fastlane, Scopus look-up
Keywords: Automotive industry; Cost estimation; Machine learning; Purchasing; Supply management; Text mining

Intelligente Versorgungssysteme für Druckluft und technische Gase - Böhm, Ralf; Javied, Tallal; Franke, Jörg (Industrie 4.0 Management : Gegenwart und Zukunft industrieller Geschäftsprozesse, 2017)

Intelligente Wohnung - Bauer, Jochen; Kettschau, Anna-Katharina; Michl, Markus; Bürner, Johannes; Franke, Jörg (Technische Unterstützungssysteme, 2015)

Intelligent fault diagnosis in Industry 4.0 - New opportunities for the sophisticated diagnosis in automated production environments - Fleischmann, Hans; Kohl, Johannes; Schneider, Michael; Franke, Jörg (wt Werkstattstechnik - Online, 2015)
The increasing complexity of sophisticated production plants poses new challenges in the field of technical maintenance. The initial step in the repair procedure is a problem root-cause analysis. As a key enabler of the Industry 4.0 cyber-physical systems form the core of novel assistant systems, which deliver more efficient diagnostic mechanisms for production facilities.
CRIS-Team Scopus Importer:2023-03-07

Intelligent vernetzte Elektronikproduktion - Bogner, Eva; Kästle, Christopher; Beitinger, Gunter; Franke, Jörg (Handbuch Industrie 4.0, 2017)

Interaction between a spray-insulation for phase separation in the winding head and the following impregnation process in insertion winding stators - Mahr, Alexander; Hartz, Barbara; Franke, Jörg (2021 11TH INTERNATIONAL ELECTRIC DRIVES PRODUCTION CONFERENCE (EDPC), 2021)
CRIS-Team WoS Importer:2022-04-29
Keywords: Electric Drive Production

Interactive Image Segmentation Using Superpixels and Deep Metric Learning for Tool Condition Monitoring - Lutz, Benjamin; Janisch, Lucas; Kißkalt, Dominik; Regulin, Daniel; Franke, Jörg (Procedia CIRP, 2023)
The optical measurement of tool wear is commonly used to monitor machining processes. Recently, deep learning methods, in particular, have been applied for the identification and segmentation of the different wear defects. For such approaches, annotated training data is required, which includes the acquisition of cutting tool images and their pixel-wise annotations. As this process is time-consuming, we propose a novel interactive image annotation method for tool condition monitoring. This is achieved by combining superpixel segmentation, deep metric learning, and human corrections. By using the interactive image annotation, manual annotation effort is reduced and mask accuracy is improved.
CRIS-Team Scopus Importer:2023-10-20
Keywords: Deep Metric Learning; Human-in-the-loop; Interactive Segmentation; Smart Manufacturing; Superpixel Segmentation; Tool Condition Monitoring

Interoperabilität realer und simulierter Produktionssysteme mittels OPC UA - Schmidl, Elisabeth; Wenk, Matthias; Russwurm, Eva; Franke, Jörg (Simulation in Produktion und Logistik 2021, 2021)
Simulation-based tools support developers in the engineering process, as they allow decision-relevant investigations to be carried out simulatively in advance. Some of these simulation studies require models that are as close to reality as possible. For their creation, data from real plants are necessary, which is associated with an increased manual acquisition and implementation effort. Furthermore, the different available simulation tools are suitable for different levels of detail. In order to use the synergies of the different tools, they have to be coupled, for which there are often no standardized interfaces yet. This paper presents a concept based on the OPC UA communication standard, which enables automated data transfer from real to simulated production plants, as well as flexible data exchange between different simulation tools<br

Intralogistics Execution System mit integrierten autonomen, servicebasierten Transportentitäten - Scholz, Michael (FAU University Press, 2019)
Der übergeordnete Forschungsinhalt der Dissertationsschrift ist die Realisierung einer intralogistischen Serviceschicht, die eine Allokation von Transportaufträgen auf einzelne Entitäten sowie eine auftragsindividuelle Routenplanung und autonome Pfadausführung ermöglicht. Dadurch wird der etablierte Prozess der innerbetrieblichen Materialflussplanung sowohl in der Planungs- als auch in der Betriebsphase durch eine Regelung substituiert. Ein Forschungsschwerpunkt stellt dabei die Konzeption eines Schichtenmodells der Software der Transportfahrzeuge dar, welches durch ein hybrides Steuerungsparadigma die Basisfähigkeiten der Entitäten zu Hauptfähigkeiten aggregiert und die Grundlage der dezentralen Auftragsallokation darstellt. Den zweiten Forschungsinhalt der Arbeit adressiert die serviceorientierte Systemarchitektur zur Digitalisierung des Arbeitsumfelds, der Routenplanung und Pfadausführung. Der dritte Teil der Forschung umfasst die Integration der intralogistischen Auftragsallokationsmethode in eine ereignisdiskrete Simulation, die ein virtuelles Abbild der Intralogistik während der Planungs- und Betriebsphase ermöglicht. Diese drei Forschungsschwerpunkte bauen auf einer detaillierten Untersuchung der aktuellen Systemlösungen zur Verteilung von Transportaufträgen auf einzelne Einheiten eines Materialflusssystems, der Digitalisierung des Arbeitsbereichs und den etablierten Verfahren der Systemauslegung in der Planungs- und Betriebsphase auf.Die Ergebnisse zeigen, dass durch den Entfall einer übergeordneten Instanz gewährleistet ist, dass unterschiedliche Transportsysteme mit unterschiedlichen Strategien und Eigenschaften in einer gemeinsamen Architektur existieren können. Der Transportauftrag wählt das für ihn geeignetste Transportmittel selbst aus, ohne dass hierfür eine explizite Regel besteht. Durch diese standardisierte Kommunikation und Softwarearchitektur ist das erforschte System sowohl in der Anzahl der Transportentitäten als auch der eingesetzten Fahrzeugarten skalierbar, was sich in dieser Form von den bekannten Ansätzen von FTS grundsätzlich unterscheidet.Die zentrale Eigenschaft der serviceorientierten Architektur ist, dass die Algorithmen zur Erfüllung der notwendigen Einzelaufgaben in unabhängige Dienste ausgelagert werden. Zudem wird durch die Systemgestaltung der Grundsatz verfolgt, den Datenaustausch zwischen den einzelnen Instanzen auf ein Minimum zu reduzieren und stets bedarfsorientiert auszulösen. Das System lässt zudem zu, den Ort und die Anzahl der physischen Einheiten, auf denen die Algorithmen implementiert sind, frei zu wählen. Dadurch ist das System sowohl in der Fläche als auch in der Anzahl der verwendeten Transportroboter unbegrenzt skalierba

Intraurethral Energy Harvesting from Urine Flow as an approach to power Urologic Implants - Benke, Elisabeth; Stoinski, Robin Thi; Preis, Alexander; Reitelshöfer, Sebastian; Martin, Sina; Franke, Jörg (43rd Annual International Conference of the IEEE Engineering in Medicine & Biology Society (EMBC), 2021)
Active urologic implants, such as bladder stimulators or artificial sphincters, are a widely-used approach for therapy of urinary incontinence. At present these devices are powered by primary batteries or conventional wireless power transferring techniques. As these methods are associated with several limitations, human body energy harvesting can be a promising alternative or complement for power supply. This paper introduces an approach to harvest energy from the urine flow inside the urethra with a mechatronic harvesting system based on a hubless flow turbine. Using a test bench approximating the flow conditions of the lower urinary tract, the feasibility of the harvesting principle is shown in-vitr
Keywords: Energy Harvesting; Implantable Medical Devices

Introduction of a comprehensive Structure Model for the Digital Twin in Manufacturing - Lechler, Tobias; Fuchs, Jonathan; Sjarov, Martin; Brossog, Matthias; Selmaier, Andreas; Faltus, Florian; Donhauser, Toni; Franke, Jörg (2020)
The discussion about the term "Digital Twin" and its associated concepts has expanded remarkably in the scientific community in recent years. In the context of industrial production, the Digital Twin refers to a holistic, linked, virtual representation of a physical entity. The spectrum of these entities ranges from individual products to specific manufacturing processes up to complex automated production systems. Due to this diversity, many authors offer different interpretations of the topic, resulting in a wide range of use case-specific models. However, a common meta-model that integrates and classifies the different aspects is still to be presented. Starting with a brief overview of developments in recent years, this paper introduces a novel Digital Twin Structure Model in the context of manufacturing. After providing an overview and explanation of the dimensions, functionality and coupling of the Digital Twin in relation to its surroundings, specific Digital Twin realizations are characterized and compared using the proposed structure model.<br
Keywords: Digital Twin; Reference Model; Industry 4.0; Product Lifecycle Management

Intuitive Gesture Control of Robots with a Sensor Arm Sleeve Based on Dielectric Elastomer Sensors - Landgraf, Maximilian; Reitelshöfer, Sebastian; Hofmann, Veit; Zimber, Fabian; Yoo, In Seong; Franke, Jörg (6th IEEE RAS & EMBS International Conference on Biomedical Robotics and Biomechatronics (BioRob), 2016)
Keywords: Biomechatronik; Dielectric Elastomer Sensors (DES); Gesture-Based Control; Human-Machine Interface (HMI); Robot Control

Intuitive Interaction with Virtual Commissioning of Production Systems for Design Validation - Metzner, Maximilian; Krieg, Lorenz; Merhof, Jochen; Ködel, Tobias; Franke, Jörg (Procedia CIRP, 2019)
As industrial production system complexity increases, digital planning and virtual commissioning become critical steps in the design validation phase of automated production systems. Virtual commissioning is used to test system behavior and control logic based on a simulation model. In this paper, we introduce a concept for facilitating non-expert interaction with such systems to further extend the applicability of virtual commissioning to the sectors of employee or customer training, hybrid system analysis and safety validation. A stereographic camera system is used to track the hands of the operator and implement them into a physics-integrated simulation environment. Hence, the operator is able to manually interact with the running virtual system at real time. The implemented system is evaluated for intuitiveness compared to a classical mouse and keyboard setup. The results show potential for the system to facilitate the non-expert interaction with advanced simulation environments.<br
Keywords: Design validation; Simulation; Mechatronics Design

Intuitive, VR- and Gesture-based Physical Interaction with Virtual Commissioning Simulation Models - Metzner, Maximilian; Krieg, Lorenz; Krüger, Daniel; Ködel, Tobias; Franke, Jörg (Annals of Scientific Society for Assembly, Handling and Industrial Robotics, 2020)
To manage complexity in modern, highly automated production systems, functional simulation for logic validation, known as virtual commissioning, is an important enabler. However, established systems for virtual commissioning are highly specialized software, which are solely used by simulation experts. In this contribution, we present a system for intuitive, user-integrated virtual commissioning. Using virtual reality, we allow for a first person experience of the simulation at runtime. By implementing a stereo-camera-based hand tracking system, we facilitate intuitive manual interaction with the simulation, including physical manipulation. Furthermore, we also integrate common human-machine interfaces, like touch panels, which are directly streamed from the industrial controller, offering the operator comparable interaction experience as with the real system. We conduct a user study quantifying the intuitiveness of interaction for defined tasks of our system compared to a standard simulation setup.<br
Keywords: Virtual Commissioning; Virtual Reality; Motion Capturing

Inverter-based hybrid compensation systems contributing to grid stabilization in medium voltage distribution networks with decentralized, renewable generation - Böhm, Ralf; Rehtanz, Christian; Franke, Jörg (Electrical Engineering, 2016)
Medium voltage grids are subject to a change in load situation due to the installation of decentralized generation plants. Predominantly load symmetry, active and reactive power as well as the required capacity of earth fault compensation are affected. Inverter-based plants as well as consumers using switching power supplies or phase control cause distortions of frequency. Simultaneously, electrical energy storage is gaining importance within rural distribution networks to compensate fluctuating generation plants. A hybrid compensation system includes a transformer, a multi-phase inverter, diverse storage systems and a communication-capable control unit, which may be connected to the control center of the distribution system operator (DSO). It is object to current research activities to design and evaluate the functions of the superordinate control unit, which has to parametrize individual components, coordinate the energy flows between them and to embed several measuring instruments. Within the present work, basic considerations for design of system control are outlined.
Keywords: Active compensation systems; Ancillary services; Earth-fault compensation; Power quality

Investigation of Alternative Applications of Electrically Functionalized Surfaces Using the Plasma-Coating-Technology - Braun, Thomas; Böhm, Ralf; Praß, Julian; Baierl, Ullrich; Hahn, Dorothea; Franke, Jörg (Advances in Production Research - Proceedings of the 8th Congress of the German Academic Association for Production Technology (WGP), Aachen, November 19–20, 2018, 2018)
Keywords: Coating; Powder; Conductor track

Investigation of drag reduction due to dimpled surfaces in narrow channels by means of flow simulations - Praß, Julian; Franke, Jörg; Becker, Stefan (Applied Mechanics and Materials, 2017)
Reduction of drag and flow resistance in systems containing moving fluids is a prominent tool to increase energy efficiency. Besides active flow control – such as moving surfaces or boundary layer suction – passive techniques such as surface patterning by means of dimples are promising since no additional energy consumer is introduced into the system. Even though the effect of drag reduction due to dimples has often been observed, the physical principals responsible for this effect are not yet understood. Most of the research concerning dimples and drag reduction published so far has been carried out experimentally, not many numerical investigations on this topic have been done. The main reason for this is that the tiny, transient flow structures generated in direct vicinity of dimples can not easily be resolved in simulations. Even in case of time dependent numerical investigations it is not clear, whether and with which method of sub-grid scale modeling Large Eddy Simulations are capable of modeling these structures sufficiently. In this work we investigated different surfaces with dimple depth to diameter ratios h/D reaching from 0.01 to 0.1 in channels of height H = 0.417D at Reynolds numbers ReD 5 830 and ReD 11 650 using steady state simulations with a k-omega-SST turbulence model. Drag reductions were observed for all setups h/D < 0:08 compared to the smooth channel. The best results were obtained with dimple depths of 4-5 % of diameter showing a slight dependence of Re which is in good agreement with literature. As the experimental investigation of the flow over dimpled surfaces is limited in spacial and temporal resolution we could demonstrate that numerical investigations give the possibility to overcome this drawback. However the solution of simulations strongly depends on numerous factors such as the discretization scheme, the numerical models and the grid used to obtain results which might be a reason for slightly varying results of such simulations found in literature.
Keywords: CFD; RANS; Dimples; Drag Reduction

Investigation of Insulation Layers on Additive Manufactured Electrical Steel Laminations in Electric Motors - Ziegler, Marco; Schafer, Paul; Wieprecht, Nico; Franke, Jörg; Kühl, Alexander (IEEE Transactions on Dielectrics and Electrical Insulation, 2023)
In this paper, the insulation properties of printed electrical steel laminations for high-efficiency electric machines are investigated. In contrast to conventionally produced electrical steel laminations made from rolled coil material, additive manufacturing from powder material allows extremely thin and complex near-net-shape geometries with no scrap material. At the same time, the printed electrical steel laminations offer the advantage that no additional cutting steps are required and specific material characteristics are adjustable which enables special machine modifications. To avoid global eddy current paths between the single sheet layers after the stacking process, the laminations must be insulated from each other in order to keep losses low, especially at high operating frequencies. This requires a sufficiently high surface insulation resistance on the sheets. Since the insulation coating cannot be applied continuously during rolling, as in conventional production, alternative approaches for application are required. The investigations characterize and evaluate potential insulation systems for additive manufactured laminations. The printed sheets are analyzed geometrically, electrically and metallurgically at first and characterized for the next process steps. Afterwards, potential insulation systems are analyzed and investigated in practical tests. The coating systems are characterized in terms of application, thickness, electrical and mechanical insulation properties, and options for further processing. This is crucial as the coating needs a sufficient level of adhesion to the substrate and allows successive bonding.
CRIS-Team Scopus Importer:2023-04-14
Keywords: Core losses; Eddy currents; Electric motors; Electrical insulation; Insulation; Lamination; Lamination; Magnetic cores; Magnetic materials; Metals; Soft magnetic materials; Steel; Three-dimensional printing

Investigation of Pressureless Sintered Interconnections on Plasma Based Additive Copper Metallization for 3-Dimentional Ceramic Substrates for Surface Acoustic Wave Sensors in High Temperature Applications - Schwarzer, Christian; Hensel, Alexander; Roth, Frederik; Franke, Jörg; Kaloudis, Michael (Proceedings - Electronic Components and Technology Conference, 2020)
Spatial circuit boards allow the integration of third dimension which results in new design freedom and in high potentials for miniaturization as well as rationalization by integration of electronics. The three-dimensional design of electronic devices can save material and cost. At high temperatures thermoplastics and thermosets, which are the standard materials of 3D-MID, reach the limits of their range of application. Ceramic substrates are a state-of-the-art material for power electronics and high-power-LED applications, mainly due to their stability in thermally demanding conditions. The focus of this publication is the evaluation of an additively manufactured surface on alumina substrates realized by a plasma-based coating method in interaction with a die attach layer using pressure-less silver sinter technology. Therefore, the deposition of copper on alumina substrates using several particle temperatures as well as additional heat treatment processes with different atmospheres were evaluated. The resulting surfaces were characterized and compared to a chemically treated surface. The formation silver sintered interconnections on the additively manufactures copper layers was investigated by destructive and non-destructive methods. Finally, the findings were transferred and used for attaching a surface acoustic wave sensor on additively metallized ceramic substrates. This publication compares the achieved results with direct copper bonded substrates (DCB) used for power electronics and describes the challenges of forming pressure-less silver sinter joints on a plasma-based copper layer for later adaption on spatial copper metallized Al2O3 substrates.
CRIS-Team Scopus Importer:2020-09-18
Keywords: additive manufacturing; high temperature applications; plasma-based copper coating; pressureless silver sintering; surface acoustic wave sensor

Investigation of pressureless sintered interconnections on plasma based additive copper metallization for 3-dimentional ceramic substrates in high temperature applications - Schwarzer, Christian; Hensel, Alexander; Roth, Frederik; Merz, Corinna; Franke, Jörg; Kaloudis, Michael (2019 22nd European Microelectronics and Packaging Conference and Exhibition, EMPC 2019, 2019)
Conventional Molded interconnect device technology with spatial circuit boards offer freedom of design as well as potential for rationalization and miniaturization by electronics integration. By integrating the third dimension into the circuit design, material and cost savings can be realized. Due to the limited application temperature of thermoplastics and thermosets, the potentials of spatial assemblies cannot be fully exploited. In the field of power electronics and LED technology, ceramic substrates are increasingly gaining acceptance for thermally demanding conditions. This publication investigates the interaction of a copper interface produced in an additive metallization process of a ceramic substrate by using the Plasmacoat® method and interconnection joints formed in a pressureless silver sintering process. Therefore, copper was deposited on different ceramic substrates and different particle temperatures as well as subsequent thermal treatment were evaluated. Silver sintering on selective coated interface was investigated for later use on a three-dimensional metallized ceramic substrate. Cross sections and Shear tests reveal that forming pressureless sintered interconnections on an additively formed copper surface is more demanding compared to common direct copper bonded (DCB) substrates.
CRIS-Team Scopus Importer:2020-02-21
Keywords: Additive manufacturing; High temperature application; Plasma coating; Silver sintering

Investigation of the influence of dimples on the resistance of overflowed plates - Praß, Julian; Wannemacher, Hagen; Franke, Jörg; Becker, Stefan (Conference on Modelling Fluid Flow (CMFF’18) - The 17th International Conference on Fluid Flow Technologies, 2018)
Keywords: CFD; Drag reduction; LES; Passive method

Investigation of the Influence of Voids n the Reliability of Solder Joints by Finite Element Method - Schwarzer, Christian; Fuchs, Dennis; Rauer, Miriam; Xu, Ping; Krügelstein, Andreas; Franke, Jörg; Kaloudis, Michael (SMTA International Conference Proceedings, 2017)

Investigation of the Influence of Voids on the Reliability of LED Solder Joints by Computer Tomography and Forward Voltage Measurement - Schwarzer, Christian; Fuchs, Dennis; Rauer, Miriam; Lang, Kurt-Jürgen; Krügelstein, Andreas; Kaloudis, Michael; Franke, Jörg (EMPC 2017, 2017)

Investigation of the laser ablation threshold for optimizing Laser Direct Structuring in the 3D-MID technology - Wang, Li; Süß-Wolf, Robert; Ulm, Michael; Franke, Jörg (ICEP-IAAC 2018 Proceedings, 2018)
Keywords: 3D-MID; LDS; Laser ablation threshold; Laser activation; Laser roughening

Investigation of the Tribological Performance of Heterogeneous Slip/No-Slip Journal Bearing Considering Thermo-Hydrodynamic Effects - Tauviqirrahman, Mohammad; Afif, M. Fadhli; Paryanto, Paryanto; Jamari, J.; Caesarendra, Wahyu (Fluids, 2021)
The slip boundary has an important influence on hydrodynamic journal bearing. However, less attention has been paid to the positive effect of slip on thermal behaviour. In this study, a computational fluid dynamics (CFD) analysis investigating the thermo-hydrodynamic (THD) characteristics of heterogeneous slip/no-slip bearings running under steady, incompressible, and turbulent conditions is presented. A comprehensive analysis is made to investigate the THD behaviours of heterogeneous slip/no-slip bearings in terms of lubricant pressure, temperature distribution, volume fraction of vapor, and load-carrying capacity when they are running under different shaft rotational speeds. The multiphase cavitation model is adopted to represent the real operational condition of the journal bearing. Numerical results show that the load-carrying capacity of the heterogeneous slip/no-slip bearing can be significantly increased by up to 100% depending on the rotational speed. It is also observed that there is an optimal journal rotational speed for maximizing the load-carrying capacity. An insightful new finding is revealed in a numerical framework, wherein it is found that by introducing the heterogeneous slip/no-slip pattern, the maximum temperature can be reduced by up to 25% in comparison with a conventional bearing.
CRIS-Team WoS Importer:2021-03-19

Investigations in Selective Laser Melting as Manufacturing Technology for the Production of High-temperature Mechatronic Integrated Devices - Syed Khaja, Aarief Hussain; Stoll, Thomas; Franke, Jörg (2016 IEEE and IMAPS IMPACT Conference, 2016)
Additive manufacturing (AM) has the potential to lead significant changes in the present state-of-the-art production processes. This provides tool-free and direct manufacturing of complex geometries simultaneously integrating various functions into components. Though AM techniques are widely used in various sectors, the applicability into electronics production has been not yet explored. In this paper, the results of the investigations towards additive manufacturing technology namely 'Selective Laser Melting (SLM)' used to produce ceramic substrates for high temperature electronic applications are summarized. This paper introduces a new substrate production technology consisting of a ceramic base with additively constructed metal conductive patterns through SLM. The process flow and the influential factors are discussed. Preliminary results in the development of demonstrator and soldering of electronics components are also summarized.

Investigations in the optimization of power electronics packaging through additive plasma technology - Franke, Jörg; Syed Khaja, Aarief Hussain; Schramm, René; Ochs, Raimund (4th CIRP Global Web Conference, CIRPe 2015, 2015)
Due to thermomechanical stresses at high temperatures and harsh environments, the interconnections between the substrate and the components in power electronics exhibit failure modes at temperatures >130°C. This contribution introduces the concept of additive plasma metallization technology for the optimization of interconnections in electronics for reliable usage up temperatures >300°C. Through the formation of intermetallic phases, diffusion soldered interconnections were realized by melting of solder paste with plasma based copper powder coating. The integration of the Plasmadust technology into standard production process delivers highly reliable interconnections with better resource management. The interconnections were characterized by building power electronic modules to demonstrate the advantages compared to state-of-the-art technologies. The potential of the Plasmadust process for power electronic production and further chances in component modification are discussed.
Keywords: Additive manufacturing; High temperature capability; Intermetallics; Plasmadust; Power electronics

Investigations of Copper Wire Bonding Capability on Plasma Based Additive Copper Metallizations - Hensel, Alexander; Kohlmann-von Platen, Klaus; Franke, Jörg (Proceedings of the 19th Electronics Packaging Technology Conference, 2017)
This paper describes and discusses a novel manufacturing process that enables an advanced top-level interconnection for power electronic applications. The commonly used aluminum bond wire process, where a friction welded connection is performed by the usage of ultrasonic on the substrate as well as on the semiconductor, is replaced by copper as a wire material. Thus, the overall performance of power electronic modules can be increased significantly because of the preeminent material characteristics of copper. However, the higher hardness and lower ductility of copper in comparison to aluminum presuppose a functional coating on the silicon layers that absorbs the high bonding forces and protects the crystal structures from shattering. Different approaches for a selective copper metallization like galvanic metallization have been investigated and provide a usable coating quality. Disadvantageously the processes are neither very flexible nor cost-effective and have also a bad environmental impact. The technology described in the following uses a current stabilized argon plasma to melt single copper particles which are then accelerated towards the substrate. Upon impact, the coating material solidifies and creates a diffusion-based adhesive layer on which the copper bonding process can be performed.
Keywords: Top Level Interconnection; Copper Wire Bonding

Investigations of selected influencing process factors for transient liquid phase soldering (TLPS) as die-attach method for automotive power modules - Ottinger, Bettina; Holverscheid, Joshua; König, Sebastian; Brunner, Annette; Müller, Lars; Goth, Christian; Franke, Jörg (International Conference and Exhibition on High Temperature Electronics (HITEC 2023), 2023)
Increasing the operating temperatures in power electronic applications cause a decreasing lifetime of the die-attach interconnection. Transient liquid phase soldering (TLPS) is able to create a reliable and high temperature resistant connection layer via diffusion processes in the form of intermetallic phases with melting points up to > 400°C. This study concentrates on a TLPS reflow-soldering process with a tin-copper-tin (Sn-Cu-Sn) layered preform. During the soldering process the influence of the selected process parameters for the Sn-Cu-Sn on the grown intermetallic phase interconnections between the preform and the components are investigated via the average void percentage and a process capability analysis (cpK). The application of mechanical pressure decreases the average void percentage below 10%. Due to the lower average void percentage the influence of the holding time, peak temperature and heating gradient are examined under low pressure. The biggest impact shows the heating gradient. With a slow heating gradient, the thermomechanical stress decreases by increasing the solubility and the average void percentage could be reduced to less than 2.7 %. In combination of the optimized selected process factors it is possible to reach a process capability value of
Keywords: die-attach; TLPS; Sn-Cu-Sn; thin solder layers; reflow-soldering process; automotive power module

Investigations of Silver Sintered Interconnections 3-Dimensional Ceramics with Plasma Based Additive Copper Metallizations - Hensel, Alexander; Schwarzer, Christian; Scheetz, Matthias; Kaloudis, Michael; Franke, Jörg (2018 IEEE 20TH ELECTRONICS PACKAGING TECHNOLOGY CONFERENCE (EPTC), 2018)
CRIS-Team WoS Importer:2019-04-12

Investigations on advanced soldering mechanisms for transient liquid phase soldering (TLPS) in power electronics - Syed Khaja, Aarief Hussain; Franke, Jörg (5th Electronics System-Integration Technology Conference, ESTC 2014, 2014)
This paper gives an overview of the optimization of the present state-of-the-art soldering technologies for diffusion soldering in power electronics, in particular for Transient liquid phase soldering (TLPS) with enhancements in process conditions to reduce the void percentage in the interconnections and at the same time accelerate the rate of intermetallic phase (IMP) formation. Addressing the difficulties in realizing a void-free TLPS joint in large-area die-attach in power electronics, the variations in soldering process parameters like temperature, pressure and time are discussed. The complete transformation of thin Sn-Cu solder interlayers (15-20μm) into CuSn and CuSn IMPs and related void information for varying solder profile variants have been explained. To evaluate the potential for TLPS process, the advanced reflow soldering mechanisms like vacuum vapor-phase soldering and over-pressure convection soldering have been investigated. Depending on the void percentages and IMP formation rate, an optimized interconnection process has been introduced which is capable of realizing TLPS joints with convectional electronic production equipment.
Keywords: die-attach; over-pressure convection soldering; thin solder layers; TLPS; vacuum vapor-phase soldering

Investigations on Measuring the Thermal Conductivity of Alumina Substrates with Laser Flash Analysis - Hensel, Alexander; Lê, Trung Anh; Sauermann, Alexander; Franke, Jörg (2018 41st International Spring Seminar on Electronics Technology (ISSE), 2018)

Investigations on processing copper-titanium powder blends via PBF-LB/M - Hecht, Christoph; Schüller, Daniel; Utsch, Daniel; Stoll, Thomas; Franke, Jörg (Lasers in Manufacturing, 2023)

Investigations on the Additive Manufacturing and Heavy Wire Bonding Capability of Selective Laser-Melted Circuit Carriers - Kästle, Christopher; Syed Khaja, Aarief Hussain; Franke, Jörg (Journal of Microelectronics and Electronic Packaging, 2017)
Additive manufacturing (AM) provides tool-free and direct manufacturing of complex geometries simultaneously integrating various functions into components. Though AM techniques are widely used in various sectors, the application into electronics production has not yet been explored. In electronics production, substrate development has high relevance due to their multifunctionality through electrically connecting components and providing mechanical support. This contribution introduces an innovative approach based on selective laser melting (SLM) in the development of high-temperature substrates through additive layered manufacturing. Furthermore, possibilities and challenges that come along with the process combination of SLM and heavy wire bonding are investigated. Wire bonding capability is analyzed on untreated as well as on postprocessed surfaces. The influence and effectiveness of various steps of postprocessing such as cleaning, sand blasting, and grinding are analyzed. Thus, interdependencies between both manufacturing process as well as postprocessing can be revealed. The effect of surface roughness and hardness of the assembly partner are investigated as well. The primary characteristics besides the bond parameters that influence the wire bonding capability are focused in this article. The process stability and the interconnection quality are evaluated by optical nondestructive laser microscopic analysis. Destructive pull and shear tests and metallographic cross sections are performed to evaluate the adhesion characteristics. By a profound understanding of all interdependencies between the two processes, a flexible manufacturing technology for power devices can be established.
Keywords: additive manufacturing; electronics packaging; heavy wire bonding; power electronic substrates; selective laser melting

Investigations on Ultrasonic Copper Wire Wedge Bonding for Power Electronics - Kästle, Christopher; Syed Khaja, Aarief Hussain; Reinhardt, Andreas; Franke, Jörg (Proceedings of the 36th International Spring Seminar on Electronics Technology (ISSE), 2013)
Driven by applications in the field of renewable energy, power distribution, consumer electronics and the automotive industry, the demand for reliable and economic power electronics packaging solutions is growing rapidly. The present study aims to display a new technology for chip top-side interconnects by using heavy wire copper wedge/wedge bonding. Therefore a response surface design of experiment study was set up to evaluate the influence of the main parameters time, ultrasonic power and bond force on the bond process quality. With this information an optimized set of machine parameters was derived, with respect to maximized pull and shear forces. Furthermore, investigations on the correlation between the bond parameters and the destructive test failure modes were conducted. All tests were accompanied by a monitoring of the tool wear-out. This allows to assess the process stability as well as the process reliability. The aim is to identify the most significant parameters and to find an optimized parameter set in order to improve future die interconnection technologies for power electronics manufacturing.
Keywords: copper wire bonding; power electronics; reliability; wedge bonding

Investigations on Wire Bonding Capability of Selective Laser Melted Structures - Kästle, Christopher; Syed Khaja, Aarief Hussain; Franke, Jörg (Proceedings of the 49th International Symposium on Microelectronics, 2016)
Keywords: Elektronikproduktion; EP

Investments in the Optimization of Energy Efficiency - A Comparative Study - Brandmeier, Markus Andreas; Krinner, Anton; Franke, Jörg (Applied Mechanics and Materials, 2016)
<use xlink:href="https://www.scientific.net/Content/app/images/public/sprite.svg#preview-icon"></use> Resource and energy efficiency of production facilities is a crucial competitive factor for industry. Due to increasing cost pressure and competition on the market, identifying and unleashing energy saving potentials as well as avoiding inefficiency is inevitable. However, for investment policy, the increase of energy efficiency is not always given highest priority. In this study we consider industry’s investment behavior for energy efficiency in relation to alternative production factors. For this purpose, this paper analyzes potential optimization issues and criteria that are taken into consideration for the decision making process for investments.
Keywords: Energy Efficiency; Investment Policy; Decision Making

Is selective laser melting (SLM) an alternative for high-temperature mechatronic integrated devices? methodology, hurdles and prospects - Syed Khaja, Aarief Hussain; Walawski, Dominik; Stoll, Thomas; Franke, Jörg (12th International Congress on Molded Interconnect Devices, MID 2016, 2016)
Molded interconnect device (MID) technology is a key enabling technology with growing markets in automotive, communications, consumer electronics through integration with lighting and sensor technologies. Additive manufacturing (AM) is also a key technology as energy, material and resource efficient alternative to conventional subtractive and formative production technologies. In this contribution, powder-based additive layered manufacturing mainly 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 MID applications. The challenge for an optimal mechatronic integrated device design is to simultaneously consider both the application-specific requirements and to integrate advantages of MID technology. This work focuses on the process development for the generation of conductive patterns on ceramic substrates by SLM technique. 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. The influences of the printed powder height, laser parameters in combination with laser scan strategies and pattern height are discussed. The hurdles and prospects of SLM as alternative for functionalization are highlighted and discussed.
Keywords: Additive Manufacturing; Ceramic substrates; Conductive patterns; High temperature; Mechatronic Integrated Devices; Molded Interconnect Devices; Selective Laser Melting

Kennzahlenbasiertes F & E-Controlling im Kontext der Elektromobilität: Methodische Erarbeitung eines Kennzahlengerüsts für das operative F & E-Controlling am Beispiel eines Maschinen- und Anlagenbauers - Mayr, Andreas; Rommel, Christian; Schaller, Veronika; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2022)
The German automotive industry is facing a radical change with regard to electromobility. The R & D departments of the established players are under great pressure to maintain their technological leadership. This article shows how a suitable set of key performance indicators can be developed for controlling the operational R & D process. The presented method is validated at a machine and plant manufacturer in the field of electromobility, the GROB-WERKE GmbH & Co. KG in Mindelheim.
CRIS-Team Scopus Importer:2022-04-08
Keywords: Controlling; Electromobility; KPI; Mechanical and Plant Engineering; Method; R & D

Knowledge-based generation of a plant-specific reinforcement learning framework for energy reduction of production plants - Schmidl, Elisabeth; Fischer, Eva; Wenk, Matthias; Franke, Jörg (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2020)
In research, there are more and more successful approaches to operate production plants more resource-efficiently and more productively with the help of reinforcement learning. An important point is the reduction of the energy demand of production plants. Instead of manually implementing complex standby strategies rigidly in a PLC, an intelligent system can train to derive decisions about the optimal energetic state of each component autonomously. Since learning in a virtual environment has decisive advantages, simulation models with sufficient accuracy are necessary. Many of the previous implementations of reinforcement learning approaches in an industrial environment are usually tailored to a specific plant. In particular, the agent's scope of action and its connection to the environment must be adapted manually for a new plant. The presented solution shows an intelligent system which automatically optimizes the virtual learning environment with the support of plant knowledge and adapts the reinforcement learning agent to the respective production plant.
CRIS-Team Scopus Importer:2020-10-30
Keywords: energy reduction; knowledge-based; reinforcement learning; virtual models

Knowledge-based Support of the Production System Design by Semantic Technologies Using the Example of the Electric Motor Production - Mayr, Andreas; Dietze, Sebastian; Herzog, Tobias; Schäffer, Eike; Schäfer, Franziska; Bauer, Jochen; Fuchs, Jonathan; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Kollisionsfreie Bewegungsgenerierung für ein Industrieroboter-Assistenzsystem auf Basis von 3D-Kameradaten - Ramer, Christina; Franke, Jörg (Internationales Forum Mechatronik 2013, 2013)
Herkömmliche Industrieroboter müssen auf Grund ihres Gefährdungspotentials strikt von Bereichen, in denen Menschen arbeiten, getrennt werden. Die Programmierung ist bei komplexen Umgebungen aufwendig, sodass sich der Einsatz nur bei ausreichend hohen Stückzahlen lohnt. Auf Grund dessen werden Industrieroboter trotz der bekannten Vorteile gegenüber manueller Ausführung - wie Schnelligkeit, Ausdauer und Genauigkeit - in vielen Bereichen nicht eingesetzt, obwohl die Unterstützung von Produktionsmitarbeitern zur Vermeidung körperlich anstrengender und monotoner Aufgaben wünschenswert wäre. Dieser Beitrag stellt einen Ansatz für ein Roboterassistenzsystem vor, bei dem über eine 3D-Kamera basierte Arbeitsraumerfassung sowie manuell definierte Hindernisse ein aktuelles Umgebungsmodell generiert und automatisch eine kollisionsfreie Bahn für einen Sechsachs-Knickarmroboter errechnet wird. Dadurch kann der Einsatz von Robotern bei nicht vorhandenem Fachpersonal zur Umprogrammierung sowie bei kleineren Stückzahlen attraktiver werden. Es ergeben sich auch weitere Anwendungsgebiete für Industrieroboter, beispielsweise zur Unterstützung leistungsgewandelter oder geminderter Personen im Erwerbsleben. Eingangsparameter der automatischen Pfadgenerierung sind die aktuelle Istposition des Roboters und eine kartesische oder achsbasierte Zielposition. Eine hierarchische Zellzerlegung des Roboterarbeitsraums berechnet hierauf kollisionsfreie Zellen sowie mittels eines angepassten A*-Algorithmus den kürzesten Weg benachbarter, freier Zellen von der aktuellen Start- zur vorgegebenen Zielposition für den Werkzeug-arbeitspunkt (TCP, Tool-Center-Point) des Roboters. Es können sowohl synchrone Point-to-Point (PTP) als auch Linearbewegungen berücksichtigt werden. Die Orientierungsänderung zwischen Start- und Zielposition wird an die Wegänderung gekoppelt. Für alle Pfadstrecken zwischen den ermittelten kartesischen Stützpunkten wird in definierten Abständen eine hierarchische Kollisionsprüfung des Roboterarms mit der Umgebung durchgeführt. Hierfür werden bei Verwendung des PTP-Modus zunächst alle gültigen Konfigurationen der Stützpunkte und die sich daraus ergebenden, realisierbaren Kombinationen bestimmt. Falls Linearbewegungen erforderlich sind oder bevorzugt werden sollen, erfolgt zudem die überprüfung der Pfadabschnitte auf singuläre Stellungen, die zu einem Verwerfen der Bahn führen. Falls ein Stützpunkt oder ein Pfadabschnitt keine gültige Konfiguration liefert, wird ein künstliches Hindernis an der TCP-Position eingefügt und auf Basis des aktualisierten Arbeitsraummodells eine erneute Zellzerlegung und TCP-Pfadsuche angestoßen. Um die notwendigen Kollisionsberechnungen zu beschleunigen, werden die Hindernisobjekte sowie der eingesetzte Roboter durch geometrisch einfache Hüllkörper umschlossen und überschneidungen mit dem Roboter hierarchisch geprüft. Neben der automatischen Bewegungsgenerierung wird im weiteren Verlauf dieses Beitrags als Erweiterung des beschriebenen Ansatzes auch die Möglichkeit einer Kollisionsüberwachung während der Roboterbewegung bei einem Einsatz ohne trennende Schutzeinrichtungen vorgestellt, sodass die Gefährdung von Menschen durch ein Anhalten des Roboters vermieden werden kann. Dabei werden auf Basis des aktuellen Arbeitsraummodells und der bekannten Roboteristposition hierarchische Abstandsprüfungen zu dynamischen Objekten und Personen durchgeführt und auf die Einhaltung eines angepassten Mindestsicherheitsabstandes geprüft.
Keywords: Assistenzsystem; Bahnplanung; ToF-Kamera; Arbeitsraumüberwachung; B|Mech

Kommunikationsbedürfnisse flexibler Produktionsanlagen - Vukovic, Petar; Franke, Jörg (VDI Berichte, 2020)
Industrial communication technology often causes difficulties during planning and operation. For this reason, many planners still rely on wired communication technology because it is easier to plan and less susceptible to failures. The trend towards digitalization and Industry 4.0 can only be successfully implemented by making production more flexible. A pervasive flexi-bilisation can only be achieved by incorporating radio-based communication technologies and is therefore becoming more and more popular. Due to a lack of know-how in radio technologies, simulations can provide optimum support in planning. The earlier these simulations are used, the lower the error costs are due to timely correction. Since the manufacturer and type of communication components are not defined at such an early stage of planning, the communication requirements of applications and devices must be used to make an optimal approximation to the later real communication. This paper presents a type of co-simulation that suggests an optimal positioning of access points based on communication needs. Furthermore, the communication needs and their characteristics are presented.
CRIS-Team Scopus Importer:2023-03-07

Kommunikation und Datenaustausch in Industrie 4.0 - Anforderungen und Fähigkeiten propagierter Kommunikationsprotokolle - Fleischmann, Hans; Gölzer, Philipp; Franke, Jörg; Amberg, Michael (wt Werkstattstechnik - Online, 2015)
Die umfassende Vernetzung intelligenter Produkte und Produktionssysteme in Industrie 4.0 ermöglicht eine dezentral agierende Produktion und die Fähigkeit zur Selbststeuerung und Selbstoptimierung. Die Standardisierung von Kommunikation und Datenaustausch nimmt an dieser Stelle eine entscheidende Rolle ein und ermöglicht die system- und wertschöpfungsübergreifende Interaktion von Entitäten. In diesem Beitrag werden formalisierte Anforderungen von Industrie 4.0 und Fähigkeiten propagierter Kommunikationsprotokolle gegenübergestell

Kontaktierung von Antrieben für die Elektromobilität - Gläßel, Tobias; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2017)
Getrieben durch die Elektromobilität und neuen Anforderungen hinsichtlich Stückzahlen, Qualität und innovativer Motorauslegungen rücken Produktionstechnologien für die Wicklung elektrischer Antriebe in den Fokus. Insbesondere etablierte Kontaktierungstechnologien, mit deren Hilfe lackisolierte Leiter elektrisch und mechanisch verbunden werden, können nur bedingt Schritt halten. Der Beitrag identifiziert aktuelle Anforderungen an Kontaktierungstechnologien und stellt innovative Lösungsansätze vor.
Keywords: Elektromobilität; elektrische Antriebe; Kontaktierungstechnologien

Kontaktierung von Antrieben für die Elektromobilität: Innovative Vorgehensweisen, Prozessketten und Technologien - Gläßel, Tobias; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2017)
Impelled by electromobility and new requirements concerning quantity, quality and innovative designs of drives, production processes for the winding of electric machines gain in importance. Especially established contacting technologies that are used to connect enameled wires electrically and mechanically are not able to keep abreast of this development. This article identifies current requirements for contacting technologies and showcases innovative solution approaches.
CRIS-Team Scopus Importer:2023-03-07

Kontaktierverfahren für lackisolierte Leiter - Gläßel, Tobias; Spreng, Simon; Franke, Jörg (2018)

Konzeption eines intelligenten Systems zur Förderung der kognitiven und motorischen Fähigkeiten im häuslichen Umfeld - Bauer, Jochen; Kettschau, Anna-Katharina; Besser, Jürgen; Jaensch, Peter; Bodendorf, Frank; Zerth, Jürgen; Franke, Jörg (8. Deutscher AAL-Kongress, 29.-30. April 2015, Frankfurt am Main, Tagungsbeiträge, 2015)
Keywords: AAL; E|Home; Kinect; Medizin; Smart Home

Kooperierende Roboter für Montageaufgaben - Reitelshöfer, Sebastian (Handbuch Fügen, Handhaben, Montieren, 2014)

Kostenminimierte, additiv gefertigte Handprothese für den Einsatz in Entwicklungsländern - Yoo, In Seong; Hawelka, Frederik; Reitelshöfer, Sebastian; Franke, Jörg (Erste Transdisziplinäre Konferenz – Technische Unterstützungssysteme, die die Menschen wirklich wollen, 2014)
Keywords: Additive Manufacturing; B|Mech; Prothetik

Kräfte-und Belastungsermittlung: Bei der Handhabung von Statorblechpaketen in der Fertigung von Elektromotoren - Schneider, Michael; Zahner, Michael; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Due to the proven low shear stress and its favorable allocation in the contact area between the individual sheets, the adhesive bonding process or baked enamel process represent packaging technologies with good electromechanical properties. For each individual application, it remains to weigh whether the lower eddy current losses justify the higher energy and time which is needed by using adhesive bonding or baked enamel. From a purely mechanical point of view, there are no concerns about the rigidity of the lamination stack during the handling process.
CRIS-Team Scopus Importer:2023-03-07

Künstliche Muskeln auf Basis von dielektrischen Elastomeraktoren (DEA) - Yoo, In Seong; Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg (Kongress und Ausstellung Medizin Innovativ – MedTech Pharma 2014, 2014)
Keywords: B|Mech; DEA; Künstliche Muskeln

Laser-assisted Selective Activation of Injection Molded Chip Packaging Devices with Thermoset Substrate Materials for Intelligent Connectivity Systems in Automobiles - Kordaß, Timo; Bachy, Bassim; Weisser, Mathias; Franke, Jörg (Procedia CIRP, 2017)
The development of sensors, such as in the automotive sector is characterized by increasing miniaturization and variety. Higher integration of functions in electrical and mechanical applications is therefore a logical consequence for further development. In this connection especially technologies can persuade, enabling high design flexibility, combination of electrical and mechanical functions and embedding of further applications. Mechatronic integrated devices are a considerable solution combining mechanical and various electrical functions in an entire component together. Specifically, the ability for insert moulding of MEMS sensor chips and the ability to create circuit carrier in nearly any shape with selective traces and laser drilled vias suite for this production method. A particular focus is on the durability of very fine conductor tracks. With increasing miniaturization especially in high temperature and high voltage applications the typical thermoplastic based substrate materials with their thin chemical plated circuits, reach boundaries in the thermal and mechanical properties. The use of thermoset materials provides a new suitable alternative in this field. The cross-linked, molecular structured thermosets obtain high temperature resistance, combined with high dimensional stability. The thermal expansion is comparative low. With appropriate selection of compound fillers, aligned laser activation parameters and suitable circuit plating system a reliable CTE composition of all materials can be achieved. Thermosetting plastic compounds with laser-activatable additives are indeed in focus of current researches. However, laser-based method for the selective activation of thermosets is currently not available on the market. As a result, it is investigated into alternative laser assisted activation methods which do not require special additives in the substrate compound for electro chemical potential. Instead an assimilated chemical palladium activation is utilized subsequently. Of particular importance is distinct and selective activation with suitable laser parameters, as well as the following electroless chemical copper and additionally galvanic copper plating with appropriate surface quality for electronic surface mount and assembly technologies. Within the article, the research results will be presented, describing the method and giving an insight into the qualified process parameters for the laser and palladium activation, their correlations among themselves as well as the implications onto the following chemical and galvanic plating.
CRIS-Team Scopus Importer:2023-03-07
Keywords: 3D-MID; chemical plating; electronic manufacturing; selective ionogenic and colloidal palladium activation; thermoset substrates

Laser-Associated Selective Metallization of Ceramic Surface With Infrared Nanosecond Laser Technology - Wang, Li; Fu, Zongwen; Süß-Wolf, Robert; Travitzky, Nahum; Greil, Peter; Franke, Jörg (Advanced Engineering Materials, 2019)

Laser Beam Melting of NdFeB for the production of rare-earth magnets - Kolb, Tobias; Huber, Florian; Akbulut, Basri; Donocik, Christoph; Urban, Nikolaus; Maurer, Dominik; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Concerning rare-earth materials additive techniques like hollow cathode discharging or magnetron sputtering have been used to produce thin films, e.g. for the application in microelectromechanical systems (MEMS). In this paper our investigations in additively processing NdFeB-powder materials by means of laser beam melting in a powder bed (LBM) in order to produce macroscopic, three-dimensional specimens are presented. In this context we explain the advantages of additively manufactured magnets in comparison to conventional production methods. Furthermore different rare-earth-material powders were characterized with respect to their suitability for the LBM process. We describe a melting or sintering of the material at varying process parameters to obtain test cubes. Those specimens were magnetized and their magnetic field was analyzed. Additionally the density and microstructure of the samples was investigated. Subsequently we conclude this paper by presenting future steps of our research.
CRIS-Team Scopus Importer:2023-03-07
Keywords: additive manufacturing; beam melting; magnetization; powder-analysis; rare-earth materials

Laser Beam Melting Of NdFeB For The Production Of Rare-Earth Magnets - Kolb, Tobias; Urban, Nikolaus; Huber, Florian; Brela, Matthäus; Maurer, Dominik; Akbulut, Basri; Donocik, Christoph; Schmidt, Michael; Franke, Jörg (Proceedings of the 6th Electric Drives Production Conference, 2016)

Laser Cleaning of Flux Residues on Copper Surfaces in Electronics Production - Hecht, Christoph; Slama, Jan Niklas; Sprenger, Mario; Haubler, Felix; Sippel, Marcel; Franke, Jörg (2022 IEEE 28th International Symposium for Design and Technology in Electronic Packaging, SIITME 2022 - Conference Proceedings, 2022)
With the manifold of different laser sources, their application in power electronics production to remove solder flux residues on direct copper bonded substrates is a promising approach to ensure adequate surface cleanliness for further processing. For many subsequent processes in the production chain of power electronic assemblies, like potting or ultrasonic wire bonding, flux residues are a major obstacle, which can lead to manufacturing and reliability problems. State of the art cleaning processes make use of water- or solvent-based liquids in a washing process, which is followed by a rinsing and drying step. As the utilized liquids have to be recycled or disposed after use and drying is often performed at elevated temperatures or in controlled atmosphere, the procedure is energy and resource consuming. An alternative way to remove flux residues and prepare the surface for further processing is a laser induced removal process. In this paper the applicability of a nanosecond-pulsed ytterbium-doped fiber laser and a continuous-wave carbon-dioxide laser to clean flux residues on copper surfaces is presented. The cleaning result was assessed via energy-dispersive X-ray spectroscopy, fluorescence measurement technology and laser confocal analysis. Results show, that the condition of the flux residues after soldering has a strong influence on the applicability of the laser sources.
CRIS-Team Scopus Importer:2023-03-07
Keywords: laser cleaning; soldering; surface cleanliness

Laser metal deposition of NiTi shape memory alloy on Ti sheet metal: Influence of preheating on dissimilar build-up - Scheitler, Christian Josef; Hentschel, Oliver; Krebs, Thomas; Nagulin, Konstantin Yu.; Schmidt, Michael (Journal of Laser Applications, 2017)
Lightweight and functional integration are two major drivers for additive manufacturing technologies. In order to integrate functionality, the use of smart materials like Nickel-Titanium (NiTi) shape memory alloys (SMAs) is a constructive approach. Generally, shape memory alloys are hard to machine and at the same time expensive materials. In this context, additive manufacturing processes like laser metal deposition are reasonable technologies to process these materials as the used powder can be recycled and near net shape geometry can be generated due to a layer-by-layer build-up process. For actuator applications, it might be reasonable to use hybrid systems, meaning just certain sections of a part are made of a shape memory material. One possible example is a NiTi shape memory element on a Ti sheet metal. Due to the varying coefficients of thermal expansion, a dissimilar build-up by means of laser metal deposition without any defects like cracks is challenging. In this paper, an approach that applies preheating is presented to generate SMA elements additively on dissimilar substrates by means of laser metal deposition. Subject of investigations are varying process parameter combinations (e.g., laser power, feed rate, and powder mass flow) and varying preheating temperatures. Based on metallographic analyses, the generated samples are evaluated. Major objective of these analyses are a defect free connection. Additionally, the forming microstructure and the occurring dilution zone are analyzed. In order to characterize the influence of different preheating strategies on the hardness and on the transformations temperatures of the generated parts, the results of hardness measurements and differential scanning calorimetry measurements are presented.
CRIS-Team Scopus Importer:2022-06-05

Laserschneiden in der Elektroblechfertigung - Franke, Jörg; Schmidt, Michael; Hubert, Markus; Risch, Florian; Tremel, Jan; Hofmann, Benjamin (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2012)

Lean 4.0 - A conceptual conjunction of lean management and Industry 4.0 - Mayr, Andreas; Weigelt, Michael; Kühl, Alexander; Grimm, Sebastian; Erll, Alexander; Potzel, Markus; Franke, Jörg (Procedia CIRP, Volume 72, 2018)

Lean information management of manual assembly processes: Creating it-based information systems for assembly staff simultaneous to the product engineering process - Lušić, Mario; Hornfeck, Rüdiger; Fischer, Christian; Franke, Jörg (Applied Mechanics and Materials, 2013)
IT-based work instruction systems help to transfer the diversity of information for workers in an effective manner. In this way, the worker is supported in the comprehension of the task, which leads to such systems receiving increased recognition from manufacturing companies. However, the currently available worker information systems make no statement about how to involve their information processing early in the development process. Because to this, the basic idea of simultaneous engineering could be feasible and a partially automated, timely and cost-effective processing of assembly relevant information could occur. The approach of the development process-oriented, computer integrated documentation and visualisation process for assembly processes (CIV process) consider this problem field and add an innovative contribution. © (2013) Trans Tech Publications, Switzerland.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly instruction; Manual assembly; Product engineering process; Simultaneous engineering; Worker information system

Learning Topometric Semantic Maps from Occupancy Grids - Hiller, Markus; Qiu, Chen; Particke, Florian; Hofmann, Christian; Thielecke, Jörn (2019 IEEE/RSJ INTERNATIONAL CONFERENCE ON INTELLIGENT ROBOTS AND SYSTEMS (IROS), 2019)
CRIS-Team WoS Importer:2020-08-21

Lebenszyklusbetrachtungen im Planungsprozess - Integration einer Lebenszyklusbetrachtung von Fertigungstechnologien im automobilen Karosseriebau - Bornschlegl, Martin; Müller, Andreas; Bregulla, Markus; Mantwill, Frank; Franke, Jörg (wt Werkstattstechnik - Online, 2016)
Die Betriebskosten von Fertigungsanlagen haben – abhängig von der jeweiligen eingesetzten Technologie – einen signifikanten Anteil an den Lebenszykluskosten. Aus diesem Grund ist es essentiell, diese bereits in der Planungsphase zu berücksichtigen, um nachhaltige Entscheidungen treffen zu können. Dabei liegt der Schwerpunkt insbesondere bei den Schulungs-, Energie- und Instandhaltungskosten. Dazu werden in diesem Fachartikel wesentliche Kostenelemente und Herausforderungen aufgezeigt.
Keywords: Automobilindustrie; Fertigungsplanung; Kostenrechnung

Lebenszykluskosten in der Digitalen Fabrik - Optimierte Entscheidungsfindung durch Erweiterung der Produktionsplanung um Folgekosten - Müller, Andreas; Bornschlegl, Martin; Mantwill, Frank; Bregulla, Markus (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2016)
Die stetig steigende Komplexität der Anlagenstruktur im Karosseriebau sowie kürzer werdende Planungsphasen stellen eine große Herausforderung an die Planungsabteilung der Automobilhersteller dar. Bei der Ausschreibung von Produktionsanlagen spielen, neben den Anschaffungskosten, die Folgekosten eine immer wichtigere Rolle. Da wesentliche Produkt- und Produktionsfaktoren in der Regel mit Simulationsmodellen vorab untersucht werden, kann durch die Ergänzung um Lebenszykluskosten die Vergabeentscheidung unterstützt werden. Dieser Beitrag stellt ein Konzept zur Unterstützung der Bewertung von unterschiedlichen Lieferanten während der Planungsphase vor.
Keywords: Lebenszykluskosten

Let Me Entertain You – A Quantitative Study on the Acceptance of Consumer Entertainment Robots - Merz, Nina; Erkan, Acelya; Bodendorf, Freimut; Franke, Jörg (54th International Symposium on Robotics, ISR Europe 2022, 2022)

Letter of Response Re: Design and fabrication of a generic 3D printed silicone unilateral CLP model - Riedle, Hannah; Lee, Justine C.; Franke, Jörg (Journal of Plastic Reconstructive and Aesthetic Surgery, 2019)

Life Cycle of a Digital Resource Twin: Meta-Modeling and Application Example - Sjarov, Martin; Lechler, Tobias; Russwurm, Eva; Fuchs, Jonathan; Faltus, Florian; Schäffer, Eike; Brossog, Matthias; Franke, Jörg (Procedia CIRP, 2021)
To provide a systematization for the emerging Digital Twin paradigm we recently introduced the Digital Twin Structure Model. In this contribution, we now utilize this model to elaborate further on the life cycle of a Digital Resource Twin: This covers the initial model generation, includes different simulation stages like software- and hardware-in-the-loop leading to virtual commissioning and the transition into serial production. The methodological considerations are accompanied by practical examples, which base on an automated assembly system. Thus, this contribution complements the Digital Twin Structure Model with an approach to design and operate a Digital Resource Twin.
Keywords: Digital Twin; Meta-Model; Production System Lifecycle Management; Virtual Commissioning

Lightweight Control Method for Dielectric Elastomer Actuators as Self-Sensing Artificial Muscles - Landgraf, Maximilian; Ollech, Johannes; Klemm, Tobias; Schaude, Janik; Reitelshöfer, Sebastian; Franke, Jörg (2nd IEEE International Conference on Cyborg and Bionic Systems (CBS), 2018)

Linear Kalman filter for dead time affected measurement signals implemented in a small scale automated guided vehicle - Lütteke, Felix; Franke, Jörg (Advances in Intelligent Systems and Computing, 2013)
This paper describes an efficient way to calculate state estimations with a linear Kalman filter, if the measurement signal is subject to a fix dead time. In addition the presented solution can handle measurement signals with arbitrarily high sample times. After the derivation of the algorithm an application with high measurement signal dead time is explained. Finally a simulation depicts the result of the algorithm being implemented on the described application. © 2013 Springer-Verlag.
CRIS-Team Scopus Importer:2023-03-07
Keywords: AGV; dead time; State estimation

Localization and grasping of small load carriers with autonomous unmanned aerial vehicles - Lieret, Markus; Lallinger, Michael; Tauscher, Markus; Franke, Jörg (Annals of Scientific Society for Assembly, Handling and Industrial Robotics, 2020)
The application of unmanned aerial vehicles (UAV) in the area of inspection, survey or urban logistics has become a rapidly developing research domain. While the feasibility of material transports with UAVs has already been shown in the scope of different projects, the payload is thereby usually transferred manually into the UAV’s load handling device. A decisive factor for the economic usability of UAVs for aerial transportation, however, is a fully automated system including the autonomous recognition and pick-up of the cargo. We therefore present a solution for the automated detection, localization and grasping of small load carriers with UAVs. The system includes a specialized load handing device, a camera-based real-time tracking solution for small load carriers and a fusion of the global and relative position measurements to achieve the in-flight positioning accuracy required for the autonomous cargo pick-u

Location dependent down-rating of voids in high power solder connections for automotive power modules - Ottinger, Bettina; Murk, Simon; König, Sebastian; Zangarro, Antonio; Müllmaier, Michael; Müller, Lars; Franke, Jörg (Conference of High Temperature Electronics Network (HITEN 2022), 2022)
The development of cost-effective, void- and lead-free high-power die attach for automotive power modules has been a major challenge for the last decades. Particularly voids at the die attach have the potential of reducing the lifetime of the interconnection between the die and the direct copper bonded (DCB) substrate demonstrably, caused by overheating of the die [1]. This study evaluates a method to determine the influence of the void position and size on the local thermal resistance of the solder interconnection. The formular of the local thermal resistance generated by using FEM simulation shows, that the permitted local maximum void size depends on the position of the void. The defined correlation factor reduces the individual void areas according to their position and thus the permitted thermal resistance is not exceeded.<br
Keywords: die attach; FEM; location; power module; soldering; voids

Logistical Integration of Smart Homes for Automated Consumer Goods Supply Based on Smart Refrigerators - Baier, Lukas; Rackow, Tobias; Donhauser, Toni; Pfeffer, Dirk; Schuderer, Peter; Franke, Jörg (Advanced Engineering Forum, 2016)
Keywords: Consumer Goods Supply; Intelligent Refrigerator; Logistical Integration; Market Research; Private Inventory Management; Smart Appliances; Smart Fridge; Smart Home; Smart Refrigerator

Long-Term Behavior of SMT Components Mounted on Printed Polymer Thick Film Pastes - Schirmer, Julian; Eisen, Kilian; Reichenberger, Marcus; Roudenko, Jewgeni; Neermann, Simone; Franke, Jörg (13th International Congress Molded Interconnect Devices (MID), 2018)

Long-term electromigration study of lead-free flip-chips with solder bumps with 50 μm or 60 μm diameter employing ENIG surface finish on both chip and substrate side - Gorywoda, Marek; Dohle, Rainer; Härter, Stefan; Wirth, Andreas; Goßler, Jörg; Franke, Jörg (46th International Symposium on Microelectronics, IMAPS 2013, 2013)
Electromigration behaviour of Pb-free solder joints in flip-chip interconnects is usually studied in highly accelerated, short-term experiments using high current density and temperature. Failures typically occur in bumps which are in cathode contact at the chip side. There are only a few published studies in which Electroless Ni-P/Immersion Au (ENIG) surface finish was used as under-bump-metallization (UBM) structure, e.g. [5]. This paper deals with the long-term electromigration behaviour of Pb-free SAC305 flip-chip solder joints with a pitch of 100 μm and solder bump diameters of 50 μn or 60 μm, respectively. The ENIG surface finish was used on both the substrate and chip side. Test specimens were subjected to several levels of temperature and current density and tested up to 16, 000 hours. The life time data is summarized using Weibull and lognormal distribution. The microstructure changes of interconnects in failed samples were subsequently investigated by SEM and EDX. Interconnects had failed due to consumption of Nickel, voids caused by electromigration, and Kirkendall void formation in the Ni-P-layer. The damage was asymmetric in respect to the current flow direction through the solder bumps and was most pronounced at the cathode side. Unexpectedly, however, the most severe damage occurred at the substrate and not at the chip side. We could show that - allowing for a few guidelines - lead-free flip-chip solder joints with 50 μm or 60 μm diameter have a sufficient electromigration life time for most applications.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electromigration; ENIG; Flip-chip; Long-term reliability; SAC305; Ultra-fine pitch

Low reflective aerosol Jet printed broadband matched load up to 67 GHz - Lomakin, Konstantin; Sippel, Mark; Gold, Gerald; Fröhlich, Jan; Helmreich, Klaus; Ankenbrand, Markus; Franke, Jörg (German Microwave Conference, 2018)
This work presents an additively manufactured termination circuit in terms of a microstrip transmission line with gradually varying conductivity applicable up to 67 GHz with an absolute reflection coefficient of less than −10 dB — and even less than −15 dB above 12 GHz. Different load conditions and manufacturing approaches are discussed and a time domain analysis supporting the design is presente

Machine Learning Approach towards Quality Control of Aerosol-Jet Printed Polymer Optical Waveguides Material - Hamjah, Mohd Khairulamzari; Thielen, Nils; Hagelloch, Jan Erik; Franke, Jörg (TENSYMP 2021 - 2021 IEEE Region 10 Symposium, 2021)
In this work, a Machine Learning approach to predict the quality of the aerosol jet printed polymer optical waveguides material is presented. For the acquisition of necessary data, a video camera system was integrated into the aerosol jet printing. An image processing tool was developed to extract printed line width and to map to the process data of the printing. For modeling, an Automated Machine Learning framework was utilized to reduce development time for a proof of concept. The final ML model reached R2 score of 74 % in predicting line width and surpassed the statistical approaches.
CRIS-Team Scopus Importer:2021-10-29
Keywords: Aerosol jet printing; Machine Learning; polymer optical waveguides

Machine Learning Based Cost Engineering of Automotive Parts – Lessons Learned - Bodendorf, Frank; Franke, Jörg (Digitale Welt 4, 60, 2019)
Strategic change management is one of the crucial fields of cost analytics in the automotive industry. Here, one important task is to explore potentials and propose measures to reduce costs of parts in the product development process. This is usually done within cost engineering and controlling departments of car manufacturing companies. The costs of part modifications are analyzed and specified usually by complex calculation methods based on a lot of input parameters describing the properties of a specific part. The calculation processes are mostly executed bottom-up. This means that the cost of a part is determined by going through many attributes and assigning and accumulating the corresponding cost estimations. These attributes comprise features of CAD designs, built-in materials as well as production sequences. That is why the traditional calculation processes are effortful and time consuming. In addition, they are predominantly carried out manually with the help of simple calculation software like spreadsheets. Actually, Machine Learning (ML) algorithms and models are occupying center stage to cope with this problem and make the process more efficient. The overall goal is to predict costs of parts in the early phase of the product development process. In this early phase the expenditure of part modifications is low, but detailed information on the structure of the part is scarce. Machine Learning models are expected to be able to learn from a large amount of historical data and predict costs without using bottom-up calculation formulas. Also, Machine Learning algorithms are expected to find out the most influencing technical and economic parameters and in this way are able to reduce the considered input data to factors that are at hand in the early stage of the development process. <br
Keywords: Automotive Industry; Cost Engineering; Machine Learning; Modeling

Machine Learning Based Quality Prediction for Solder Paste Dispensing in Electronics Production - Thielen, Nils; Pan, Wenzhe; Piechulek, Niklas; Voigt, Christian; Meier, Sven; Schmidt, Konstantin; Franke, Jörg (Proceedings of the 24th Electronics Packaging Technology Conference, EPTC 2022, 2022)
Transfer of solder paste for manufacturing of electronic assemblies is a crucial process step for final product quality. While the most common technologies are stencil- and screen-printing, dispensing of solder paste can be seen as an alternative, especially for three-dimensional circuit carriers and small-scale production. Nonetheless, dispensing lacks in process speed and suffers from anomalies in the process, such as insufficient solder paste transfer. In this paper, we investigated a data-driven approach to predict quality of these solder depots in terms of height, area and volume including both process data and previous dispensing quality itself. This work contains three steps. First, a suitable data set was generated by means of Design of Experiment and the dispensing steps based on it. The data was first statistically analyzed. For the model development primarily using automated machine learning (AutoML) is chosen as an approach, in order to reduce model development time and hyperparameter tuning. Furthermore, a deep neural network is trained as a comparison. The performance of the AutoML model ensemble outperforms both the neural network and the statistical benchmark for all quality parameters considered: height, area and volume of the deposited solder paste. The best models offer an R2 score of 0.71 for height, 0.89 for area and 0.81 for solder paste volume, on a separated test dataset. Thus, indicating strong correlation.
CRIS-Team Scopus Importer:2023-03-07

Machine Learning in Electric Motor Production - Potentials, Challenges and Exemplary Applications - Mayr, Andreas; Seefried, Johannes; Ziegler, Marco; Masuch, Michael; Mahr, Alexander; von Lindenfels, Johannes; Meiners, Moritz; Kißkalt, Dominik; Metzner, Maximilian; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)
Artificial intelligence entails a wide range of technologies, which provide great potential for tomorrow's electric motor production. Above all, data-driven techniques such as machine learning (ML) are increasingly moving into focus. ML provides systems the ability to automatically learn and improve from data without being explicitly programmed. However, the potential of ML has not yet been tapped by most electric motor manufacturers. Therefore, this paper aims to summarize potential applications of ML along the whole process chain. To do so, basic methods, potentials and challenges of ML are discussed first. Secondly, special characteristics of the application domain are outlined. Building on this, various ML approaches directly relating to electric motor production are presented. In addition, a selection of transferable approaches from related sectors is included, as many ML approaches can be used across industries. In conclusion, the given overview of different ML approaches helps practitioners to better assess the possibilities and limitations of ML. Moreover, it encourages the identification and exploitation of further ML use cases in electric motor production. <br
Keywords: electric motor production; machine learning; artificial intelligence; potentials; challenges; applications

Machine Learning in Production – Potentials, Challenges and Exemplary Applications - Mayr, Andreas; Kißkalt, Dominik; Meiners, Moritz; Lutz, Benjamin; Schäfer, Franziska; Seidel, Reinhardt; Selmaier, Andreas; Fuchs, Jonathan; Metzner, Maximilian; Blank, Andreas; Franke, Jörg (Procedia CIRP, 2019)
Recent trends like autonomous driving, natural language processing, service robotics or Industry 4.0 are mainly based on the tremendous progress made in the field of machine learning (ML). The increased data availability coupled with affordable computing power and easy-to-use software tools have laid the foundation for using such algorithms in a wide range of industrial applications, e.g. for predictive maintenance, predictive quality or machine vision. However, a systematic guideline for identifying and implementing economically viable ML use cases in manufacturing industry is still missing. In particular, there is still a lack of a structured overview of concrete, industry-specific best practices that can be easily transferred to one’ s own production. Hence, this paper aims to summarize various existing application scenarios of ML from a process and an industry sector perspective. The process point of view mainly covers the main manufacturing process groups of DIN 8580, handling operations according to VDI 2860 as well as selected cross-process approaches. From an industry sector perspective, application scenarios from various subsectors such as the production of electronics, electric motors, transmission components and medical devices are outlined.<br
Keywords: machine learning; data analytics; artificial intelligence; production; manufacturing; assembly; potentials; challenges; applications; Industry 4.0

Magnetic stray field measurement of magnetic specimen - Heyder, Andreas; Tenner, M.; Meyer, Alexander Wilhelm; Abersfelder, Sandra; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
The production of electromagnetic actuators is a complex procedure with a great number of potential influences on the process and hence the quality of the final product itself. The necessity for an in-line magnetic production system which allows an efficient monitoring of the magnetic properties of work pieces at different stages of the production process thus becomes apparent.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electromagnetic actuator; in-line measurement; magnetic process control; magnetic stray field measurement; test bench development; three-dimensional magnetic field measurement

Manufacturing automation for automotive wiring harnesses - Nguyen, Huong Giang; Kuhn, Marlene; Franke, Jörg (Procedia CIRP, 2021)
Within the paradigm shift of electrification and autonomous driving, the automotive wiring harness has evolved to a safety-critical system, as it is responsible for the energy and information provision for safety-critical functions like steering and braking. To fulfill higher requirements concerning quality and safety, manufacturing automation is the key-enabler because it supports transparent, reproducible, and comprehensible processes. However, the state-of-the-art wiring harness manufacturing process is characterized by a high degree of manual work reaching up to 90%. In this paper, we systematically identified and clustered research publications and patents for wiring harness manufacturing automation, and analyzed the automation concepts as well as underlying technologies. Based on the findings, we derive research gaps that require an in-depth investigation in the future to increase the degree of automation in the wiring harness manufacturing.<br
Keywords: Automotive wiring harness; Autonomous driving; Manufacturing automation; Deformable linear objects; Systematic review; Assembly

Manufacturing Imperfections in Electric Motor Production with Focus on Halbach Array Permanent Magnet Rotor Assembly - Meyer, Alexander Wilhelm; von Lindenfels, Johannes; Mayr, Andreas; Franke, Jörg (8th International Electric Drives Production Conference (EDPC), 2018)

Manufacturing Influences on the Motor Performance of Traction Drives with Hairpin Winding - Gläßel, Tobias; Bachinski Pinhal, Daniel; Masuch, Michael; Gerling, Dieter; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)
To face the challenges posed by the electrification of the automotive drivetrain, rotating electrical machines are getting an impetus to innovation. Thus, machines of high power density are required to be manufactured cost-effectively in a large-scale production. To meet these requirements, the application of stators with hairpin windings is focused in industry and research institutions, as they show potentials to realize improved copper fill ratios in the armature slots. In addition, this technology also is seen as one possibility to substitute the elaborate winding technologies that often feature a lack of reproducibility, by bending, assembling and joining processes. During the design of electric drives, the influences of deviations of manufacturing processes on its performance usually are not taken into account. This particularly applies to the technology of hairpin windings, whose manufacturing requires a large number of bending and contacting operations. These process steps may influence the electrical properties of the winding, changing the behavior of the electrical machine. For this reason, the objective of this paper is to identify deviations in the manufacturing processes of hairpin windings and to validate their influence on the performance of the drive. For this purpose, measuring systems are set up which make it possible to quantify the influence of bending and contacting processes on the electrical properties of the winding by means of highly accurate resistance measurements. As next step, a simulation is set up to map the production influences on the hairpin winding to the machine’s efficiency. Based on simulation studies, the influences of the manufacturing imperfections on the engine performance become visible. <br
Keywords: Electric Drives Production; Hairpin Windings; Manufacturing Influences

Manufacturing influences on transmission efficiency and thermal integration of resonant circuit modules of inductive power transmission systems for electric vehicles - Weigelt, Michael; Jordan, Sophia; Manger, Johanna; Kneidl, Maximilian; Masuch, Michael; Kühl, Alexander; Franke, Jörg (2023 IEEE Wireless Power Technology Conference and Expo, WPTCE 2023 - Proceedings, 2023)
Electromobility is the backbone of modern emission-neutral transportation systems. Wireless energy transfer via induction is the associated complementary technology that significantly improves the user-friendliness of energy supply in various use cases such as static or dynamic wireless power transfer (WPT). The functionality of WPT for electric vehicles is extensively demonstrated, but no automatable manufacturing processes exist to produce them in large scale. Therefore, this paper describes the manufacturing process chain of coil modules of inductive power transfer (IPT) systems and presents quality criteria for these coil systems. Using structured design of experiment (DOE), the manufacturing influences on the quality of the coil modules are presented and quantified. In addition, embedding concepts of the ground assembly (GA) capacitor configuration are qualitatively evaluated.
CRIS-Team Scopus Importer:2023-09-22
Keywords: Assembly; Automotive; E-Road; Inductive Power Transfer; IPT; Production Systems; Wireless Power Transfer (WPT)

Manufacturing of 3D mechatronic systems with plasma technology - Schramm, René; Franke, Jörg (Smart Systems Integration - 8th International Conference and Exhibition on Integration Issues of Miniaturized Systems - MEMS, NEMS, ICs and Electronic Components, SSI 2014, 2014)
CRIS-Team Scopus Importer:2023-03-07

Manufacturing of Ceramic Based Mechatronic Integrated Devices Using Laser-Direct-Structuring - Bräuer, Philipp; Stoll, Thomas; Muckelbauer, Martin; Häußler, Felix; Hensel, Alexander; Franke, Jörg (2022 IEEE 9th Electronics System-Integration Technology Conference (ESTC), 2022)
This paper introduces a convenient way to manufacture ceramic based mechatronic integrated devices by means of laser-direct-structuring (LDS). The process to achieve that, consists of pretreatment, laser structuring, chemical metallization, and assembly. In the experiments, the alumina samples are blackened to enable the interaction with the laser beam. For the structuring process, a Nd:YAG laser with a wavelength of 1,064 nm and a maximum power of 17 W is used. The design of experiment (DoE) in the first place includes 54 different laser parameter settings. Subsequently the best parameter of the DoE with respect to surface roughness after laser structuring, chemical copper metallization thickness and surface roughness after chemical copper metallization is used to produce antenna samples. The surface roughness after laser structuring and after chemical copper metallization is aimed to be as low as possible to optimize the properties of the antennas. Parameters resulting from the DoE show a copper metallization layer thickness of 8.78 μm after 120 minutes of chemical metallization. These parameters are then used to manufacture microstrip and coplanar waveguide samples which are measured with a microscope to verify the dimension conformity with the test design. <br
Keywords: MID; Ceramics; Lasers; Mechatronics; Antennas

Manufacturing of Polymer Optical Waveguides for 3D-Opto-MID: Review of the OPTAVER Process - Hamjah, Mohd Khairulamzari; Zeitler, Jochen Tobias; Eiche, Yannic; Lorenz, Lukas; Backhaus, Carsten; Hoffmann, Gerd Albert; Wienke, Alexander; Kaierle, Stefan; Overmeyer, Ludger; Lindlein, Norbert; Bock, Karlheinz; Franke, Jörg (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
In order to meet the increasing demand for data transmission over short distances of up to 100 m, the Optical Assembly and Connection Technology for ComponentIntegrated Bus Systems (OPTAVER) research group, funded by the German Research Foundation (DFG), developed a process for the additive manufacturing of three-dimensional optical waveguides. The research group focuses on design and modeling, simulation, and manufacturing polymer optical waveguides to produce 3D-Opto-Mechatronic-Integrated Devices (3D-Opto-MID). Inside 3D-Opto-MID, an optical coupler is presented based on an asymmetrical coupling principle. This paper reviews the entire process chain and the corresponding research results of the OPTAVER process.
CRIS-Team Scopus Importer:2021-03-26
Keywords: 3D-Opto-MID; aerosol jet printing; asymmetrical optical bus coupling; flexographic printing; functionalization; printed multimode waveguides; Raytracing; wave propagation method

Manufacturing of polymer optical waveguides using self-assembly effect on pre-conditioned 3D-thermoformed flexible substrates - Hoffmann, Gerd-Albert; Wolfer, Tim; Zeitler, Jochen Tobias; Franke, Jörg; Suttmann, Oliver; Overmeyer, Ludger (Advanced Fabrication Technologies for Micro/Nano Optics and Photonics X, 2017)
Keywords: Optics; Design; Printing; Waveguide

Manufacturing process curve monitoring with deep learning - Meiners, Moritz; Kuhn, Marlene; Franke, Jörg (Manufacturing Letters, 2021)
Modern manufacturing plants generate large volumes of data from production processes to monitor and control them. Besides the volume, the complexity of data rises, and thus, new approaches like machine learning and deep learning move into focus to extract the desired information. In assembly, which is critical for final product quality, various processes use curves for quality monitoring. However, there is currently little research on extracting further information from those process curves. Therefore, this paper proposes a deep learning approach for process curve monitoring. The usability is demonstrated through six joining processes and benchmarked to automated machine learning.
CRIS-Team Scopus Importer:2021-10-22
Keywords: Assembly; Machine learning; Mechanical joining; One-dimensional convolutional neural network; Process curve monitoring

Manufacturing Techniques for Improved Electric Traction Drives - Bickel, Benjamin; Mahr, Alexander; Meixner, Sebastian; Bäumler, Markus; Franke, Jörg (Proceeding of the 26th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM), 2016)
The use of electric drives as traction motors in electric vehicles creates new requirements in the well-known business area of industrial electric machines. These include demands for high power at reduced sizes combined with increased efficiency rates. The winding, as the heart of the electric drive, determines the electro-magnetic characteristics of the complete motor for the most part. Consequently, there is the need to optimize the winding design in order to increase the power density and efficiency of the machine. Most highly optimized machines are produced in small batch sizes and require a vast amount of manual work, which increases the time required for and the cost of manufacturing. Thus, the common manufacturing methods must be analyzed and optimized in order to develop efficient drive windings. Alternative solutions for the manufacturing for improved diamond coil windings are reviewed in experiments and evaluated with respect to their advantages within an integral production line.<br

Maschinelle Lernverfahren zur Digitalisierung manueller Ablese- und Messvorgänge - Mühlbauer, Matthias; Würschinger, Hubert; Hanenkamp, Nico; Funtikov, Svyatoslav (Industrie 4.0 Management : Gegenwart und Zukunft industrieller Geschäftsprozesse, 2023)
Im Fabrikbetrieb kommen häufig Messmittel zum Einsatz, bei denen noch keine automatische Abspeicherung oder Weiterverarbeitung des gemessenen Werts erfolgt. Mitarbeiter müssen in diesem Fall den Messwert manuell er-fassen und weiterverarbeiten. Folgend wird ein Ansatz zur optischen Erfassung und Digitalisierung von Messwerten mithilfe Maschineller Lernverfahren vorgestellt. Dies soll zur Entlastung der Mitarbeiter beitragen, Ablesefehler reduzieren sowie eine automatisierte Dokumentation ermöglichen.<br
Keywords: Digitalisierung; Bildverarbeitung; Maschinelles Lernen; Objekterkennung

Maschinelles Lernen in der Elektronikproduktion: Herausforderungen und Anwendungsmöglichkeiten - Thielen, Nils; Schmidt, Konstantin; Seidel, Reinhardt; Franke, Jörg (GMM-Fb. 94: EBL 2020 – Elektronische Baugruppen und Leiterplatten, 2020)
Aufgrund der fortschreitenden Miniaturisierung sowie zunehmenden Anforderungen an Zuverlässigkeit und Leistung, steigt auch der weitere Optimierungsbedarf in der Oberflächenmontage (SMT). Der erreichte Standard erschwert diese Optimierung jedoch. Der hohe Automatisierungsgrad in der SMT-Produktion und die bereits existierenden großen Mengen an Prozess- und Inspektionsdaten erleichtern die Anwendung von Methoden Künstlicher Intelligenz (KI), wie Maschinellem Lernen (ML) und Computer Vision. Um Stillstandszeiten von Anlagen zu reduzieren, die Qualitätskontrolle zu verbessern und Werkzeuge zur Prozessanpassungen zu integrieren, können datenbasierte Verfahren nicht triviale Zusammenhänge von Prozess- und Anlagenparametern erkennen. Dieses Paper gibt eine Übersicht von ML-basierten Modellen, ihren Vor- und Nachteilen, sowie Grenzen in der Elektronikproduktion. Des Weiteren wird eine Literaturübersicht zu bereits veröffentlichten Forschungsansätzen vorgestellt. Diese werden in Abhängigkeit zu ihren Anwendungsfeldern und ihrer Relevanz zur Prozessoptimierung in verschiedene Kategorien unterteilt. Im letzten Teil des Papers werden Anwendungsfälle und die damit verbundenen Herausforderungen betrachtet. Diese schließen bedarfsorientierte Reinigungen von Maschinen, Vorhersagemodelle für Fehler und Klassifizierung von Defekten sowie deren Ursachen mit ein. Die zugehörige Auswertung fokussiert den Aufwand der Modellimplementierung, Möglichkeiten für anlagen- und linienübergreifende Kommunikation und einen Vergleich mit etablierter statistischer Prozesskontrolle. Aufbauend wird die Einsatzmöglichkeit der ML-Modelle für den entsprechenden Anwendungsfall in der Elektronikproduktion bewertet.<br
Keywords: Machine Learning; SMT; Electronics Production

Maschinelles Lernen in der Produktion - Kißkalt, Dominik; Mayr, Andreas (2021)
Die Verfahren des maschinellen Lernens eröffnen neue Möglichkeiten, Daten nutzbringend auszuwerten und dadurch den Intelligenzgrad von Maschinen und Anlagen zu erhöhen. Dieser Beitrag umreißt, mit welchen Herausforderungen der Einsatz von maschinellem Lernen im Produktionsumfeld einhergeht, und zeigt aktuelle Trends sowie beispielhafte Anwendungsfälle au
Keywords: Machine Learning; Produktion; Fertigung

Matching Corporate Software Engineers and Data Offerings - from Discovery to Recommendations - Martens, Benedikt; Franke, Jörg (2022 19th International Joint Conference on Computer Science and Software Engineering, JCSSE 2022, 2022)
Data plays an essential role in developing software, especially in large and complex projects. Data can be collected from different stages of the software life cycle and can form the basis for decision-making and thereby the success of projects. With increasingly automated and tool-supported development landscapes, the amount of data that is generated and accessible rises as well. Large corporate software projects, in addition to generating data also give rise to a high volume of offerings based on the data. These aim to increase the value generated by stakeholders like developers, requirement engineers, and testers. The offering land-scape brings new complexities and difficulties with it and needs to be managed, systematized, and brought to the correct person at the right time in order to create value. In this publication, models for abstracting and generalizing data offerings and data consumers are presented and their applicability is verified in a global corporate software environment. In addition, approaches for matching data offerings and consumers are presented. Our results show that offerings and consumers can be abstracted and matched using a recommender system.
CRIS-Team Scopus Importer:2022-09-02
Keywords: corporate learning; decision making; empirical software development; recommender system; software artifacts; software life cycle

Matching in decentralized two-sided markets via Blockchain-based deferred acceptance - Funk, Felix; Franke, Jörg (2021 3rd Conference on Blockchain Research Applications for Innovative Networks and Services (BRAINS), 2021)
Ever since the technology was first introduced, Blockchains have been considered as a potential enabler for decentralized markets. Starting with the initial usage of cryptocurrencies on conventional platforms, to the development of fully decentralized, smart-contract-based platforms and highly specific applications running on consortium chains, this potential has already been realized. However, competitive, two-sided peer-to-peer matching markets in which financial aspects play a secondary role have been researched less. In this paper, we propose the integration of the classic deferred acceptance algorithm with Blockchain technology in order to leverage the benefits of its clearinghouse architecture for sets of peers without requiring an intermediary. We furthermore present a prototypical implementation including a sealing mechanism and discuss its functionality and scalability.
Keywords: Distributed ledger; Scalability; Blockchains; Peer-to-peer computing; Market design; Allocation; Matching

Matching of Mechanical Properties of Biological Tissues and Technical Materials for the Fabrication of Anatomical Models by Material Jetting - Preis, Alexander; Riedle, Hannah; Benke, Elisabeth; Franke, Jörg (Proceedings of the 14th International Joint Conference on Biomedical Engineering Systems and Technologies - Volume 1: BIODEVICES, 2021)
Realistic, high-fidelity anatomical models with material properties corresponding to those of human tissue can be used for surgical planning and training, medical education and medical device testing and validation. Conventional manufacturing of anatomical models is a time consuming, and expensive process, which nevertheless is not able to fully mimic the complex nature of the human body regarding geometry and mechanical properties. To create models closer to reality in a fast and cost-effective way, additive manufacturing, especially the process of material jetting, can be a solution. Utilizing this process, it is possible to fabricate multi-color, multi-material objects with complex geometries, high resolution, and even gradients in material properties. To replicate the mechanical properties of biological tissues, they must be matched with the technical materials or material combinations available for the utilized manufacturing process. Therefore the authors propose to conduct measu rements according to standardized testing procedures like ISO 37 for tensile and ISO 48-4 for indentation tests, which allows matching to the manufacturing materials and thus will result in the possibility to create more accurate replicas of the human body that provide realistic haptic feedback.<br
Keywords: Surgical Models; Anatomical Models; Surgical Training; Medical Education; Medical Device Evaluation; Biomechanics; Biomechanical Testing; Additive Manufacturing; 3D Printing; Material Jetting; Standardization

Material identification for smart manufacturing systems: A review - Lutz, Benjamin; Kißkalt, Dominik; Regulin, Daniel; Hauser, Tobias; Franke, Jörg (Proceedings - 2021 4th IEEE International Conference on Industrial Cyber-Physical Systems, ICPS 2021, 2021)
In industrial manufacturing, a variety of different materials are used to manufacture goods in a cost-efficient manner. In situations where multiple materials are being used, such as compound parts, the machining becomes particularly challenging, as various materials require the adaption of the respective machining process. A similar parameter adaption is necessary for the machining of material batches with varying machinability. However, the specific material batch or the exact transition point among multiple materials for compound parts might not be known. Thus, to enable material-specific parameter adaption for smart manufacturing systems, a material identification system is necessary. In this research, proposed material identification approaches are reviewed regarding the application scenario and the proposed solution. Based on the findings, a taxonomy is derived for classifying material identification tasks in one of the five categories: major material, material sub-class, specific material, material grade, and material batch. Analyzing the signals used for identification, it is shown that surface images, force data, and vibration data are most commonly used. Whereas images are often used as single modality, the remaining signals are typically paired in multi-modal sensing approaches. Focusing on the decision-making system, it can be seen that, especially for the time-series signals, extensive preprocessing and feature engineering is carried out to derive meaningful features from the raw signals. Consecutively, threshold systems or machine learning models are used for decision making. The most commonly investigated algorithms are artificial neural networks, support vector machines, and k-nearest-neighbor.
CRIS-Team Scopus Importer:2021-08-20
Keywords: Machining; Material identification; Process monitoring; Smart manufacturing

Measurement of shear forces during gripping tasks with a low-cost tactile sensing system - Agarwal, Rishabh; Bergbreiter, Sarah (RoboSoft 2019 - 2019 IEEE International Conference on Soft Robotics, 2019)
To grasp and manipulate complex objects, robots require information about the interaction between the end effector and the object. This work describes the integration of a low-cost 3-axis tactile sensing system into two different robotic systems and the measurement of these complex interactions. The sensor itself is a small, lightweight, and compliant silicone based capacitive sensor. The soft and conformable design of the sensor allows it to be integrated within a variety of end effectors and locations on those end effectors (e.g. wrapped around a finger). To improve integration and data collection of the sensors, a custom interface board and ROS (Robot Operating System) package were developed. Sensor data has been collected from four different tasks: 1. pick and place of non-conductive and conductive objects, 2. wrist-based manipulation, 3. peeling tape, and 4. human interaction with a grasped object. In the last task, a closed loop controller is used to adjust the grip force on the grasped object while the human interacts with it.
CRIS-Team Scopus Importer:2019-06-21

Measurements for Onboard Communication in a High-Speed Train up to 330 km/h for Selected Scenarios at 2.45 GHz - Lichtblau, Johann; Lurz, Fabian; Weigel, Robert; Kölpin, Alexander (2019 IEEE Radio and Wireless Symposium (RWS), 2019)

Mechanical modifications of soft actuators for the use as a dynamic iris implant - Martin, Sina; Schwab, Jürgen; Caballero Lopez, Patricio; Benke, Elisabeth; Reitelshöfer, Sebastian; Franke, Jörg (43rd Annual International Conference of the IEEE Engineering in Medicine & Biology Society (EMBC), 2021)
Aniridia is a condition characterized by defects or absence of the iris. Since the eyes are a central point of attention in the human face, these deformities are often covered with cosmetic implants. However, patients suffer from the static pupil diameter of these implants, resulting in high light sensitivity or inadequate night vision. Therefore, we present a functional iris implant based on dielectric elastomer actuators. These electric drives are characterized by a silent and continuous adaptation as well as a small construction volume and a low heat emission. Since they normally exhibit in-plane uniaxial motion, this displacement must be focused to operate similarly to the iris sphincter. Therefore, we investigated possible mechanical modifications of the setups to generate a directional motion. The results of the study are presented and discussed.Clinical Relevance- The proposed system design enables the functional treatment of aniridia and other accidental iris defects. In addition, the system serves as a basis for later developments of e.g. functional lenses that allow focus adjustment.
Created from Fastlane, Scopus look-up

Mechanical qualification and microstructural analysis of alumina produced by material extrusion - Utsch, Daniel; Bründl, Patrick; Franke, Jörg; Erdogan, Hüseyin (Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2023)
Ceramics with their advantageous properties such as high thermal conductivity and electrical insulation are attractive to circuit carrier materials in electronics production. Using material extrusion (MEX-AM) for reasons of flexible manufacturing, this work produces green bodies with low surface roughness, which is necessary for subsequent metalizing to create 3D circuit carriers. Systematic variation of post-treatment profiles (debinding, sintering) leads to different microstructures and thus influences mechanical properties. A comprehensive mechanical qualification of ceramic samples produced with MEX-AM and post-treated differently has been carried out, in which tensile, compressive and flexural strength are analyzed. Using the Anderson Darling Test, it is shown that statistical methods standardized for conventional ceramics are applicable to additively manufactured specimens. A mean bending fracture strength comparable to conventional ceramics could be achieved combining a low heating rate profile for debinding with a two-step sintering (TSS) approach, which resulted in reduction of grain size, as SEM analysis confirmed.<br

Mechatronic Behavior Analysis of a Customized Manufacturing Cell - Paryanto, Paryanto; Brossog, Matthias; Merhof, Jochen; Franke, Jörg (Proceedings of the 7th World Conference on Mass Customization, Personalization, and Co-Creation (MCPC 2014), Aalborg, Denmark, February 4th - 7th, 2014, 2014)
Analyzing the mechatronic behavior of a manufacturing cell used in a customized manufacturing process is a difficult task with numerous obstacles. Therefore, a method that can be easily used for developing and optimizing a customized manufacturing cell, i.e., universal contacting module (UCM) cell, for the in-circuit testing of electronic modules is desired. In this paper, we present a convenient method using multi-domain simulation tools for analyzing the mechatronic behavior of the UCM cell. The UCM cell, which consists of mechatronic components such as a six-axis industrial robot and conveyor systems, were successfully modeled, simulated, and validated under several payloads. This work also presents a modeling procedure that can be applied by system engineers with a basic background in control systems for analyzing the mechatronic behavior of manufacturing cell components.
Keywords: Multi-Domain Simulation; mechatronic behavior; manufacturing

Mechatronic Integrated Devices Produced by Laser Direct Structuring on Powder-Coated Aluminum Substrates - Kuhn, Thomas; Krügelstein, Andreas; Franke, Jörg (Proceedings of 39th International Spring Seminar on Electronics Technology (ISSE 2016), 2016)
The present study aims to display new potentials for Mechatronic Integrated Devices (MID) by using a powder coating system (PCS) that enables the laser direct structuring process (LDS) on metal-based substrates. Therefore, in a first step, relevant process parameters for the production of MID based on powder-coated aluminum plates were identified. Afterwards, comparative investigations between powder-coated specimen and conventional thermoplastic LDS-MID using liquid crystal polymer (LCP) and thermally conductive polyamide (PA mXD6) as substrate material were executed. The results show clear advantages of the powder-coated parts regarding current carrying capacity of circuit traces. Furthermore, the mechanical characterization of the different specimen indicates considerably higher adhesion strength between metallization and powder coating than between metallization and the investigated thermoplastic materials.
Keywords: 3D-MID; E|P; LDS; Mechatronic Integrated Devices

Mechatronische Integrationspotenziale durch MID - Goth, Christian; Kuhn, Thomas (Räumliche elektronische Baugruppen (3D-MID), 2013)
Keywords: 3D-MID; E|P

Mediendichte Umhausung spritzgegossener, räumlicher elektronischer Schaltungsträger im Montagespritzguss - Goth, Christian; Heinle, Martina; Franke, Jörg; Drummer, Dietmar (PLUS - Produktion von Leiterplatten und Systemen, 2012)
UnivIS-Import:2015-03-09:Pub.2012.tech.FT.FT-KT.medien

Method for Vectorial Robot Movement Determination Enabling Accuracy Improvements - Buschhaus, Arnd; Franke, Jörg; Apel, Nicky (2015 IEEE International Conference on Control, Automation and Robotics, 2015)
Promising approaches for robot accuracy improvements belong to the visual servoing methods. These methods comprise closed-loop control systems, which utilize sensors to guide the robot relative to visible features of a work-piece. However, the known methods show limitations regarding their usability for highly accurate applications or tasks without a predetermined process pathway. To overcome this problem, at FAPS a system for high-speed monitoring of the work-piece's movement is investigated. The system enables a closed-loop control of the robots motion, if a deviation between actual and planned movement is determined. For the actual movement determination, a highly efficient and accurate image data processing system, based on a vectorial movement deter-mination of fiducial markers is developed. In this context, a highly efficient and geometrical accurate actual state determi-nation constitutes a significant challenge. Experiments show, that the system allows a position determination in an area of ten microns at a frequency faster than 500 Hz, thus enabling a reactive robot control and accuracy improvement.
Keywords: A. Buschhaus; B|Mech; Image processing; robot control; Visual servoing

Methodical Comparison of Alternative Powertrain Technologies for Long-Distance Mobility Using Germany as an Example - Weigelt, Michael; Mayr, Andreas; Kühl, Alexander; Franke, Jörg (WEVJ (World Electric Vehicle Journal), 2019)
The main barriers to the wide acceptance of electric vehicles, such as the limited driving range or the high acquisition costs, are to be countered by various technology alternatives for the powertrain of the future. Promising developments include improved battery technologies, fuel cell technologies or a constant power supply of the vehicle while driving, for example through dynamic inductive charging. In this context, a holistic technology comparison would contribute to a comprehensive and understandable information situation by making the heterogeneous technological concepts comparable with regard to different evaluation criteria. Therefore, this work describes the basic assumptions of the proposed holistic comparison of alternative powertrain technologies for long-distance mobility. Relevant framework conditions are structured and a procedure for the evaluation of infrastructure expenditures is shown. Building on this, a selection of key performance indicators is defined and explained. The proposed KPI framework is applied to a passenger car in the economic area Germany. The results show that by using electrified roadways, ecological as well as economic advantages against other alternative powertrain designs can be derived.<br

Methodik zur frühzeitigen Integration prozessspezifischer Einflussfaktoren aus der automatisierten Montage in die Auslegung funktionskritischer Komponenten - Russwurm, Eva; Faltus, Florian; Laukotka, Fabian; Schwan, Lukas; Brossog, Matthias; Krause, Dieter; Franke, Jörg (Proceedings of the 32nd Symposium Design for X, DFX 2021, 2021)
Dimensioning function-critical components in automated manufacturing systems is critically and depends on the handled objects as well as the handling processes. The processes lead to mechanical forces and torques on the components. During engineering, these process-depending forces are mostly unknown and thus, are taken into consideration by using high safety factors. In order to reduce the resulting over-dimensioning a novel methodology, which facilitates all available information and new methods, is presented. By combining a Co-Simulation, consisting of FEM- and Multi-Physics-Simulations, with MBSE-approaches the digitized workflow iteratively converges the parameters of these critical components. A hardware-in-the-loop-approach assists gathering specific data and validating the final design-parameters.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Automated manufacturing; Co-Simulation; Methodic design/dimensioning; Model based Systems Engineering; Process-effects

Methodik zur monetären Bewertung von Serviceplattformen - Eine systematische Analyse von Plattforminteraktionen - Hartner, Fabian; Kerker, Sebastian; Bodendorf, Frank; Kirchner, Markus; Uebler, Moritz; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2021)
In order to be able to implement industrial services independent of time and location, digital, data-based services are increasingly being offered on online platforms. This article presents a methodology for the monetary valuation of different functionalities of service platforms, which also includes additional platform-specific effects, such as value co-creation. Users of the methodology receive a calculation tool that considers not only savings for the platform operator in interactions but also the added value for the customer.
Created from Fastlane, Scopus look-up

Methodology for digital planning and virtual validation of retroactively automated assembly systems - Metzner, Maximilian; Barth, Fabienne; Bönig, Jochen; Franke, Jörg (Tagungsband des 4. Kongresses Montage Handhabung Industrieroboter, 2019)
Disruptive technologies such as lightweight robots, autonomous mobile robots as well as powerful sensor and control technologies enable flexible and economical automation of production processes. Therefore, they are suitable for retroactive automation of existing systems. During retrofit, the conversion or commissioning time is a critical factor, which is why exact planning and virtual validation are necessary. Novel, digital tools offer extensive assistance for this task. This article describes a systematic and application-oriented methodology for continuous digital planning and validation of these automation solutions up to a turnkey robotic automation system. A validation of the proposed methodology in an electronics production scenario is describe
Keywords: Adaption Planning; Robot Simulation; Factory Automation

Methodology for the Analysis of Platform-Based Value Networks in the Manufacturing Industry - Hartner, Fabian; Link, Felix; Fuchs, Jonathan; Franke, Jörg (Production at the Leading Edge of Technology, 2021)
Platform companies such as Amazon and Uber have changed the business-to-consumer (B2C) sector at a rapid pace. In the context of the digitization of products and processes, the importance of digital business-to-business (B2B) platforms is increasing. Emerging digital platforms form a value network between business entities and are characterized by mostly complex business relationships of different partners. Therefore, a clear representation of the respective value network on a business level is fundamental for the understanding and analysis of digital platforms and their underlying business models. In this publication, existing models and modeling languages for value networks were analyzed for the requirements in digital platform-based businesses. As a result, this publication provides a methodology that reveals the complex relationships of platform-based value networks based on defined roles and relationships for an improved and consistent understanding of platforms in the manufacturing industry.
Keywords: Digital platforms; Value networks; Modelling; Ecosystems

Methodology Towards Computer-aided Testing of Complex Mechatronic Systems: A Case Study about Assembling a Train System - Meinel, David; Paryanto, Paryanto; Franke, Jörg (Procedia CIRP, 2016)
Domain-specific computer-aided analysis of technical systems has become well-established. Nominal and worst case scenario behavior of systems can be modelled sufficiently, however, still lacking the ability of simulating the behavior of technical systems as a whole, combining single-domain subsystems. Therefore, unpredictable failure can occur, which displays the demand for computer-aided system analysis. To counteract the foresaid, a concept has been proposed, which enables sufficient designing and implementing a highly flexible model landscape. It serves the process from comprehending a technical system's specifications and functions towards an executable model structure, using the Modelica-based modelling software SimulationX. Since its future application remains to be tested in the aftermath, the concept will exemplarily be applied on a flexible train simulator.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Computer-aided testing; Flexible simulator; Mehatronic system modelling; SimulationX; Train modelica; Train simulator; Train systems

Methods-Energy Measurement – An approach for sustainable energy planning of manufacturing technologies - Bornschlegl, Martin; Bregulla, Markus; Franke, Jörg (Journal of Cleaner Production, 2016)
Given the self-declared energy and environmental protection objectives of many car manufacturers responsible companies must use energy-efficient production technologies. The running costs of production sites are a decisive factor in the overhead of automotive production. Therefore, it is important for many operators to reduce those costs in a sustainable way. For this purpose, they attempt to reduce both the energy consumption costs and CO2 emissions of production systems. However, most components of the energy costs are determined during the very early phases of the product creation process. To achieve an estimation of the energy consumption in this early planning stage, a new suitable forecasting method is required. Therefore, this paper presents an approach for determining the prospective energy consumption by using Methods-Energy Measurement combined with defined energy reference cycles for manufacturing technologies. With this approach, key performance indicators are defined, and the production technologies are divided into basic energy consumers. The average energy values will be determined empirically by using the defined energy reference cycles. With these data, the energy demands for different scenarios are calculated. Thereby, it is possible to estimate the potential energy consumption of complex manufacturing cells. The designed method is validated within a case study of a modern automotive body shop. In summary, the approach contributes to identify and realize sustainable solutions in advance and thus increase the profitability of a factory.
Keywords: Energy management; Energy efficiency; Energy measurement; Life-cycle costing; Methods-Energy Measurement; Production planning

Microservice-based architecture for engineering tools enabling a collaborative multi-user configuration of robot-based automation solutions - Schäffer, Eike; Mayr, Andreas; Fuchs, Jonathan; Sjarov, Martin; Vorndran, Johannes; Franke, Jörg (Procedia CIRP, 2019)
Microservice (MS) architectures, especially in combination with micro front ends, are a modern, scalable and sustainable approach to software development. The modular development of individual components and the possibility of a simple, collaborative and iterative development represent a strategic advantage for companies. In addition, the MS approach allows the consistent use of current technologies, whereby new software functionalities can constantly be included. In this paper, the potentials of MS for engineering tools are shown using the example of a web-based configurator for robot-based automation solutions. On the one hand, the implemented prototype illustrates a possible MS architecture pattern and, on the other hand, clarifies how new functionalities such as the collaborative multi-user configuration or different role-based configuration sessions are enabled by such a concept. Using the example of the web-based configuration platform, it is finally shown how a MS architecture contributes to better development and easier deployment of engineering software solutions based on the divide and conquer principle.<br
Keywords: microservice; micro front end; architecture; multi-user; collaborative; configuration; robotic automation system; engineering tool

Migration zur intelligenten Produktion - Darstellung eines Entscheidungsmodells zur Integration cyberphysischer Systeme in den Maschinen- und Anlagenbau - Gutjahr, Jonas; Bogner, Eva; Bäumler, Markus (Industrie 4.0 Management : Gegenwart und Zukunft industrieller Geschäftsprozesse, 2017)
Die Produktion der Zukunft findet in einer Umgebung statt, in der intelligente Cyber-Physische Systeme (CPS) das technologische Fundament zur Realisierung einer effizienten und damit wettbewerbsfähigen Produktion bilden. In Verbindung mit dieser Zukunftsvision fehlt es Entscheidungsträgern aus der Industrie, insbesondere des Mittelstands, jedoch an initialen Angriffspunkten für die Implementierung von CPS und der damit verbundenen nachhaltigen Migration zur Smart Factory. Es wird eine Methodik vorgestellt, mit welcher aus unternehmensstrategischer Sicht potenzielle CPS-Einsatzfelder identifiziert werden können und eine damit verbundene Investitionsentscheidung unterstützt werden kann. Das Ziel liegt in der Befähigung eines Entscheidungsträgers zu einer strategischen Auswahl von CPS-Anwendungslösungen im Rahmen von beispielhaften Gestaltungsmöglichkeiten.
Keywords: Cyber-physische Systeme; Entscheidungsmodell; Migrationsprozess; Smart Factory

Minimization of energy needs in the industry of electric drives manufacturing considering process-related temperature curves - Kohl, Johannes; Spreng, Simon; Hofmann, Benjamin; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
The energy consumption within electric drives manufacturing is dominated by heating and cooling processes. As the optimization of these processes is often only based on the product quality, in practice a lot of consecutive heating up and cooling down phases can be observed leading to strongly varying temperature curves. Thus, high energy needs as well as long throughput times have to be approved. In order to overcome these obstacles and to optimize the products' temperature curves the Institute for Factory Automation and Production Systems developed a simulative approach on the basis of the program Tecnomatix Plant Simulation. The implemented Temperature Module is hereby not only able to track a product's temperature through the whole simulated production chain. It as well communicates with the energy module presented in [6] and [7]. This enables the possibility to calculate energy needs on the basis of the actual product temperature. For that purpose an example located in the field of electric stator manufacturing is investigated.
CRIS-Team Scopus Importer:2023-03-07
Keywords: discrete event simulation; electric drives manufacturing; energy efficiency; temperature simulation

Mit Simulation die Produktion optimieren - Franke, Jörg; Feldmann, Klaus; Brossog, Matthias (Automation Day - 28.10.2009, 2009)
UnivIS-Import:2015-04-16:Pub.2009.tech.FT.FT-FAPS.mitsim

Mobile ions entering the IGBT gate oxide - electrical detection and failure localization by lock-in thermography - Käsbauer, M.; Dreher, P.; Sippel, Marcel; Schmidt, R. (Microelectronics Reliability, 2023)
Small mobile ions, especially sodium and potassium are known to have the ability to infiltrate and move within gate oxide layers of silicon MOS devices. The ion transport in silicon oxide is either a temperature-driven, isotropic diffusion process, or an electrical ion current in presence of an electric field. Therefore, the high temperature gate bias test with negative polarity provides ideal conditions to identify the presence of mobile ions in the gate oxide of IGBT and MOSFET. Mobile ions in sufficient concentration can severely affect the electric characteristics, such as the turn-on and turn-off behavior of the MOS channel, by creating a shift in the gate threshold voltage or excessive sub-threshold currents. This paper shows several examples of how mobile ions can get into the gate oxide, e.g., via cracks in top side metallization, or by corrosive attack of cap layers. All these different failure modes develop the same electrical failure signature after temperature and/or gate bias stress. During the investigations on mobile ions, a special lock-in thermography method was developed that allows to localize the defect sites in the semiconductor by taking advantage of exclusive excitation of MOS cells affected by mobile ion contamination. Finally, after defect localization, further analytical methods can be applied to identify the exact nature of the access path to the gate oxide. Based on the test and analytical routine described above, a special test method was developed that allows to evaluate the permeability of the semiconductor chip top side structures towards mobile ions and to check for weak spots and potential leakage paths.
CRIS-Team Scopus Importer:2023-11-10
Keywords: Contamination; HTGB; Intrusion; Lock-in thermography; Mobile ions; Nondestructive; Power electronics; Transfer characteristic

Mobile Roboterplattformen: Ein neues Team in der Fabrik - Rinck, Philipp; Blank, Andreas; Zäh, Michael; Franke, Jörg (2017)
Im Rahmen des Forschungsverbunds FORobotics wird untersucht, welche Potenziale sich in der Produktion durch einen Einsatz von mobilen Roboterplattformen ergeben. Die einzelnen Roboter sollen autonom Aufgaben in der Fabrik übernehmen und sich dabei ad-hoc zu kooperierenden Teams zusammenschließen. Durch Kombination der Mensch-Roboter-Kooperation und ortsflexiblen Robotersystemen kann eine neue Form des Teams innerhalb der Fabrik definiert werden. Ein solches Team hat das Potenzial zur Flexibilitäts- und Produktivitätssteigerung entlang der Wertschöpfungskette. Im Rahmen des Forschungsvorhabens FORobotics werden mobile Roboterteams fokussiert, die durch ihre Kooperation Wertschöpfung liefern. Hierbei stehen Aspekte wie Assistenz bei manuellen Tätigkeiten, Mensch-Roboter-Kollaboration sowie Roboter-Roboter-Kollaboration in der Logistik und Montage im Vordergrund.
Keywords: BFS Verbundforschungsprojekt FORobotics; ad-hoc kooperierende Roboterteams; mobile Roboterteams; Mensch-Roboter-Kollaboration

Model Factory for Additive Manufacturing of Mechatronic Products: Interconnecting World-Class Technology Partnerships with Leading AM Players - Yoo, In Seong; Braun, Thomas; Kästle, Christopher; Spahr, Michael; Kestel, Philipp; Wartzack, Sandro; Franke, Jörg; Bromberger, Jörg; Feige, Erhard (6th CIRP Conference on Learning Factories, 2016)
The additive manufacturing (AM) model factory’s aim is to establish a leading-edge learning academy for the digital and generative production of innovative mechatronic products, where the complete value chain is integrated on a single site. Short courses and deep dives enable easier access to the state of the art technologies and increase the awareness for their potentials. Anchored in key industries such as automotive, aerospace, and medical by major OEMs and regional SMEs, the AM model factory cooperates with world-class partners and leading market players. This paper displays the model factory’s setup, selected technologies, exemplary courses, and benefits.

Model improvement through real data connection for Virtual commissioning in ramp-up management of scalable production systems - Kampker, Achim; Wessel, Saskia; Lutz, Nicolas; Heine, Simon; Mayr, Andreas; Kuhn, Alexander (Procedia CIRP, 2021)
The electric motor production of the automotive industry faces numerous challenges due to weak sales and uncertain sales forecasts of the electric vehicle. To meet these challenges, scalable production systems have increasingly been set up. The application of virtual commissioning to scalable production systems holds increased potential since the deterministic simulation model can be improved step by step through the inclusion of real data. Therefore, a concrete process model is to be created describing how virtual commissioning can be made even more effective through real data connection. The validation is carried out on an application from material handling technology.
CRIS-Team Scopus Importer:2021-06-04
Keywords: Digital factory; Electric motor production; Real data connection; Scalable production systems; Virtual commissioning

Modeling and optimization of laser direct structuring process using artificial neural network and response surface methodology - Bachy, Bassim; Franke, Jörg (International Journal of Industrial Engineering Computations, 2015)
Laser direct structuring (LDS) is very important step in the MID process and it is a complex process due to different parameters, which influence on this process and its final product. Therefore, it is very important to use a reliable model to predict, analyze and control the performance of the (LDS) process and the quality of the final product. In this work we develop mathematical models by using Artificial Neural Network (ANN) and Response Surface Methodology (RSM) to study this process. The proposed models are used to study the effect of the LDS parameters on the groove dimensions (width and depth), lap dimensions (groove lap width and height) and finally the heat effective zone (interaction width), which are important to determine the line width/space in the MID products and the metallization profile after the metallization step. We also study the relationship between the LDS parameters and the surface roughness which is very important factor for the adhesion strength of MID structures. Moreover these models capable of finding a set of optimum LDS parameters that provide the required micro-channel dimensions with the best or the suitable surface roughness. A set of experimental tests are carried out to validate the developed ANN and the RSM models. It has been found that the predicted values for the proposal ANN and RSM models were closer to the experimental values, and the overall average absolute percentage errors were 4.02 % and 6.52%, respectively. Finally, it has been found that, the developed ANN model could be used to predict the response of the LDS process more accurately than RSM model.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Artificial neural network; LDS process; MID process; Modeling; Response surface methodology

Modeling and Simulation Techniques for Energy Behavior in Production Systems: A Review and Systematic Taxonomy - Barth, Martin; Russwurm, Eva; Gutwald, Benjamin; Kunz, David; Reichenstein, Tobias; Franke, Jörg (2023 IEEE 2nd Industrial Electronics Society Annual On-Line Conference (ONCON), 2023)
So far, existing publications related to energy simulation of production systems predominantly focus on application or simulation aspects, with a particular emphasis on discrete event simulation (DES) of process chains. However, the modeling of energy aspects, even beyond the typical DES area, is crucial for a successful simulation project in terms of analyzing and optimizing energy-saving potentials within the industry. Therefore, this paper focuses on major techniques used to model the energy behavior of production systems across all levels of production systems, from individual components to a network of factories. Through a structured literature review, we identified the primary modeling techniques and typical characteristics for energy modeling and structured them in the form of a taxonomy.<br
Keywords: Industries; Industrial electronics; Production systems; Systematics; Taxonomy; Production facilities; Behavioral sciences; Modeling; Simulation; Energy Efficiency

Modeling, Simulation and Manufacturing of Polymer Optical Waveguides by Using the OPTAVER Process - Reitberger, Thomas; Zeitler, Jochen Tobias; Backhaus, Carsten; Hoffmann, Gerd-Albert; Wienke, Alexander; Lorenz, Lukas; Bock, Karlheinz; Wolter, Klaus-Jürgen; Suttmann, Oliver; Overmeyer, Ludger; Lindlein, Norbert; Franke, Jörg (Applied Industrial Optics: Spectroscopy, Imaging and Metrology 2019, 2019)
This paper shows the modeling, simulation and production of polymer optical waveguides using the OPTAVER process. The additive manufactured multimode waveguides with their typical cross-section of a circle shape are of low cost and high-performance.<br

Modelling of Energy Storage Devices and Converters for Energy Flow Simulation in Plant Simulation - Tur, Bogac; Fischer, Eva; Franke, Jörg; Bergs, Christoph; Schulze, Christine (ASIM 2019, 2019)

Model of a Power-to-Gas System with Fuel Cell in a Mixed Integer Linear Program for the Energy Supply of Residential and Commercial Buildings - Ebell, Niklas; Bott, Andre; Beck, Tobias; Bürner, Johannes; Praß, Julian; Franke, Jörg (Applied Mechanics and Materials, 2017)
In the field of energy supply for residential and commercial buildings, the optimal operation, system configuration and sizing of generation as well as storage technologies are essential steps for cost-efficient investments. In current research, flexibility options for electricity from growing renewable energies attract attention. One of the considered options is the power-to-gas technology in combination with fuel cells. Linear Programs for optimal system operation exist for example for distributed energy systems. In this study we propose a Mixed Integer Linear Program of a power-to-gas unit consisting of an electrolyzer, a fuel cell and a hydrogen storage. For the fuel cell a minimum load and a non-linear efficiency curve is taken into account. The non-linear efficiency curve is approximated by piecewise linearization. Bilinear products in the modeling of the efficiency curve are being substituted to maintain full power plant sizing and operation functionality. Different fuels, such as natural gas and hydrogen to be converted in the fuel cell, are implemented as well. As a result, we show that a detailed model of the non-linear efficiency curve of a fuel cell leads to more accurate results concerning the system operation. The configuration of system components in the observed energy system changes. Especially the battery system experiences a change in sizing and operation. However, solving time of the model is increasing dramatically. Our results demonstrate a valuable approach to compare the results of a Linear Program to a Mixed Integer Linear Program. Hence giving the possibility to evaluate the necessity of detailed over simplified models regarding calculation of cost-effectivenes
Keywords: power-to-gas; Mixed Integer Linear Program; optimal operation; system configuration; fuel cell; load-dependent efficiency

Modular Robot Software Framework for the Intelligent and Flexible Composition of Its Skills - Heuss, Lisa; Blank, Andreas; Dengler, Sebastian; Zikeli, Georg Lukas; Reinhart, Gunther; Franke, Jörg (Advances in Production Management Systems. Production Management for the Factory of the Future, 2019)
Current trends such as mass customization necessitate an agile and transformable production. In this context, robotic technologies are seen as a key enabler. But, to date, industrial robots lack the flexibility to easily adapt to changing needs. Therefore, a modular skill-based software framework aiming for free configurability is presented here. A generic task control allows varying incoming tasks to be processed, based on the actual skills of the robot. In this way, the flexible composition of a robot’s skills can be achieved, according to the actual situation.<br
Keywords: Autonomous robots; Configurability; Skills

Morphologically intelligent dielectric elastomer sensors based on micro-structured electrodes as resistive strain elements - Martin, Sina; Reitelshöfer, Sebastian; Franke, Jörg (Proceedings of SPIE - The International Society for Optical Engineering, 2023)
Dielectric elastomer sensors (DES) are compliant systems that, allow the detection of geometric changes caused by external forces. However, a simple DES provides only the amplitude of a deformation. In order to fully describe a tensile force vector, it is necessary to characterize it by its length, direction, and origin. Therefore, there are many approaches to improve the information that can be obtained from the sensor, such as arranging DES patterns or modifying the impact of the applied mechanical force by using external components. To improve and parallelize the information provided by the mechanical deformation of the system, we aim to combine the operation principle of structured resistive strain sensors with the capacitive properties of DES. By structuring the electrodes with different patterns and combining two dissimilar electrodes in one setup, it is possible to detect the length and direction of a force vector with one sensing element. To study the patterning and its effect on resistive and capacitive signals, we use an aerosol jet printing technique that allows selective deposition of a conductive ink. The printed lines show a higher resistance increase when forced perpendicular to the pattern and vice versa, which allows to distinguish the direction and the type of applied force. In this study, the influence of printing parameters and signal interpretation for different forces are investigated. The results show that the combination of resistive and capacitive signals allows discrimination between different motions.
CRIS-Team Scopus Importer:2023-10-20
Keywords: aerosol jet printing; Dielectric elastomer sensors; embodied intelligence; morphological intelligence; strain sensors; structured electrodes

Motivation and Approach to Establish a Comprehensive Community in Project Engineering - Götz, Johannes; Brossog, Matthias; Franke, Jörg (Concurrent Engineering Approaches for Sustainable Product Development in a Multi-Disciplinary Environment, Proceedings of the 19th ISPE International Conference on Concurrent Engineering, 2013)
Project engineering covers all technical related activities, processes and tools to realize a customer specific solution (e.g. industrial plant or factory) from conceptual design to commissioning. Consequently, project engineering determines both, costs and quality of customer-specific projects. Due to growing complexity of industrial projects and rising cost pressure caused by new players in the market, companies specialized on project engineering have to improve quality and reduce costs of their engineering results continuously. This paper shows how engineering companies can be supported in mastering these challenges by joining together in an `Engineering Community'. Therefore, a community model consisting of the three key variables `content & activities', `stakeholders' and `infrastructure' has been develope
Keywords: Engineering; Knowledge network

Multi-Agent Reinforcement Learning for the Energy Optimization of Cyber-Physical Production Systems - Bakakeu, Jupiter; Baer, Schirin; Klos, Hans Henning; Peschke, Joern; Brossog, Matthias; Franke, Jörg (Artificial Intelligence in Industry 4.0, 2021)
This chapter proposes an artificial intelligence based solution for the efficient operation of a heterogeneous cluster of flexible manufacturing machines with energy generation and storage capabilities in an electricity micro-grid featuring a high volatility of electricity prices. The problem of finding the optimal control policy is first formulated as a game theoretic sequential decision making problem under uncertainty, where at every time step the uncertainty is characterized by future weather dependent energy prices, high demand fluctuation, as well as random unexpected disturbances on the factory floor. Because of the parallel interaction of the machines with the grid, the local viewpoints of an agent are non-stationary and non-Markovian. Therefore, traditional methods such as standard reinforcement learning approaches that learn a specialized policy for a single machine are not applicable. To address this problem, we propose a multi-agent actor-critic method that takes into account the policies of other participants to achieve explicit coordination between a large numbers of actors. We show the strength of our approach in mixed cooperative and competitive scenarios where different production machines were able to discover different coordination strategies in order to increase the energy efficiency of the whole factory floor.
CRIS-Team Scopus Importer:2021-03-19

Multi-Agent Reinforcement Learning for the Energy Optimization of Cyber-Physical Production Systems - Bakakeu, Jupiter; Kißkalt, Dominik; Franke, Jörg; Baer, Shirin; Klos, Hans Henning; Peschke, Joern (Canadian Conference on Electrical and Computer Engineering, 2020)
The paper proposes an artificial intelligence-based solution for the efficient operation of a heterogeneous cluster of flexible manufacturing machines with energy generation and storage capabilities in an electricity micro-grid featuring high volatility of electricity prices. The problem of finding the optimal control policy is first formulated as a game-theoretic sequential decision-making problem under uncertainty, where at every time step the uncertainty is characterized by future weather-dependent energy prices, high demand fluctuation, as well as random unexpected disturbances on the factory floor. Because of the parallel interaction of the machines with the grid, the local viewpoints of an agent are non-stationary and non-Markovian. Therefore, traditional methods such as standard reinforcement learning approaches that learn a specialized policy for a single machine are not applicable. To address this problem, we propose a multi-agent actor-critic method that takes into account the policies of other participants to achieve explicit coordination between a large numbers of actors. We show the strength of our approach in mixed cooperative and competitive scenarios where different production machines were able to discover different coordination strategies in order to increase the energy efficiency of the whole factory floor.
CRIS-Team Scopus Importer:2020-12-25
Keywords: Actor-Critic; Autocurricula; Flexible Manufacturing System; Industrie 4.0; Load Management; Multi-Agent System; Proximal Policy Optimization; Reinforcement Learning

Multifunctional use of functional mock-up units for application in production engineering - Hauf, Dominik; Sus, Sebatian; Strahilov, Anton; Franke, Jörg (Proceedings - 2017 IEEE 15th International Conference on Industrial Informatics, INDIN 2017, 2017)
This paper describes how Functional Mock-up Units (FMUs) can be used multifunctional in production engineering applications. There are presented three different examples: Example one shows the behavior simulation of mechatronic components in Virtual Engineering (VE). The second application example describes the energy simulation of an automated production system while Virtual Commissioning (VC). The last presented use case of FMU implementation is an application after engineering phase, while real production runtime (digital twin). Additional to the application examples the methodical and historical background of the integration of FMUs is presented.
CRIS-Team Scopus Importer:2023-03-07
Keywords: afunctional mock-up interface; behavior simulation; cyber physical system; digital twin; energy simulation; mechatronic simulation

Multimodal Feedback to Support the Navigation of Visually Impaired People - Seßner, Julian; Dellert, Franziska; Franke, Jörg (2022 IEEE/SICE International Symposium on System Integration (SII), 2022)

Multimodal Feedback to Support the Navigation of Visually Impaired People - Seßner, Julian; Dellert, Franziska; Franke, Jörg (2022 IEEE/SICE International Symposium on System Integration, SII 2022, 2022)
Various assistance systems have been developed to overcome limitations of orientation and mobility of visually impaired people. A crucial aspect is to convey the generated information in a safe and intuitive way without disturbing or overstraining the remaining sensory perception. This paper presents the development and evaluation of a multimodal feedback for a navigation assistance system. The feedback modulation enables comprehensive navigation based on sensory environment detection and interpretation and can be adapted to the user's preferences. For this purpose, navigation instructions received by the path planning algorithm of the assistance system are converted into signals and transmitted to the user via auditory and vibrotactile interfaces. The generated feedback and the respective signal are evaluated in a subject study under constant conditions to test reliability. With few limitations, the functionality of the feedback approach can be proven.
CRIS-Team Scopus Importer:2022-03-25

Multi-Model Machine Learning based Industrial Vision Framework for Assembly Part Quality Control - Schwab, Maximilian; Madeline-Derou, Charles; Klarmann, Steffen; Thielen, Nils; Meier, Sven; Franke, Jörg; Chintanippu, Sandan; Stork, Wilhelm (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2022)
The predicted drop in prices for automotive sensors and their increasing demand are putting pressure on sensor suppliers. One possible solution is to reduce production costs by expanding automation. Nevertheless, visual quality control in particular is a process step that is often performed by human inspectors, even in the age of Industry 4.0. Software solutions can currently not be used for all types of sensor assembly quality control. This is mainly due to the difficulty of detecting both structural and logical errors and evaluating their severity. We present a machine learning-based software framework that is able to mimic the methodical behavior of a human in error detection and assessment. The framework is based on three types of models, an object recognition model, an anomaly detection model, and a segmentation model. All models are based on convolutional neural networks. An initial proof of concept (PoC) has been performed to prove the usefulness of the models and shows promising results. The initial anomaly detection model is able to reduce the number of objects to be manually tested by 16%. The object detection and segmentation are still in progress and could not be evaluated yet. In addition, a dataset preparation method is presented to use data from industrial practice and relabel it with information from an inspector survey.
CRIS-Team Scopus Importer:2022-11-25
Keywords: anomaly detection; assembly part; autoencoder; machine learning; object detection; quality control; segmentation

Multi-Objective Design Space Exploration for the Integration of Advanced Analytics in Cyber-Physical Production Systems - Bakakeu, Jupiter; Fuchs, Jonathan; Javied, Tallal; Brossog, Matthias; Franke, Jörg; Klos, H.; Eberlein, W.; Tolksdorf, S.; Peschke, J.; Jahn, L. (2018 IEEE INTERNATIONAL CONFERENCE ON INDUSTRIAL ENGINEERING AND ENGINEERING MANAGEMENT (IEEE IEEM), 2018)
CRIS-Team WoS Importer:2019-02-27

Multi-objective parameter optimization for stacking and sintering of screen-printed magnetic sheets - Schmidt, Alexander; Wieprecht, Nico; Weinrich, Tim; Franke, Jörg; Kühl, Alexander (Production Engineering, 2023)
Screen printing enables the production of very thin magnetic sheet laminations in near net shape geometry. This minimizes material waste in production and simultaneously reduces losses during machine operation and in-creases geometric design freedom. The subsequent sintering process step is particularly relevant, since the geometrical and magnetic properties are defined, and relevant process costs are caused by the heat treatment. This paper presents the requirements of the debinding and sintering process for magnetic sheets and identifies relevant influencing factors to achieve defined product specifications in multiple iterations, using design of experiments. It focuses on the influencing factors furnace atmosphere, sintering temperature, holding time and stacking height and their impact on the magnetic and geometric properties of sintered magnetic sheets.<br
Keywords: Electric motor; Heat treatment; Magnetic sheets; New materials; Sintering; Soft magnetic materials

Multi-perspective analysis of monetary effects of information sharing between supply chain partners - Bodendorf, Frank; Franke, Jörg (Industrial Marketing Management, 2022)
While most of information sharing literature in supply chain (SC) management mainly deals with the analysis and quantification of information sharing to upstream actors by downstream actors, this paper quantitatively deals with the two-way information sharing. The setup of a dyadic SC is considered. Informed by complexity, principal-agent and information sharing theory a hybrid simulation model combining dynamic programming and agent-based modeling is built to measure and analyze the effects of information sharing scenarios (none / one-sided / two-sided) on the profit in the entire SC as well as of the individual participating actors. The results show that information exchange is valued differently depending on the actors‘ point of view in the SC. For both the entire SC and the manufacturer, the highest profits can be expected from two-way information exchange, while the supplier maximizes its profits when solely sharing upstream information. We prove that due to higher expected profits, information sharing can enable companies to achieve higher performance in the SC. Additionally, we show that different power structures, which are reflected by transfer pricing between the actors, do not result in any change in information sharing preferences. Building on the study's results theoretical and practical implications are derived.
CRIS-Team Scopus Importer:2022-06-10
Keywords: Hybrid simulation; Information sharing; Supply chain management

Mutter Natur als Vorbild: Bionische Lösungen treiben die Automatisierung an - Landgraf, Maximilian; Reitelshöfer, Sebastian; Franke, Jörg (2013)
Keywords: B|Mech

My new colleague has artificial muscles: a DEA based approach for inherently compliant robotic systems - Yoo, In Seong; Landgraf, Maximilian; Ramer, Christina; Reitelshöfer, Sebastian; Ziegler, Christian; Franke, Jörg (Production Engineering, 2014)
Keywords: Artificial muscles; Compliant actuators; Dielectric elastomer actuators; Electroactive polymers; Human–robot collaboration; Safe robotic systems

Nahfeldlokalisierung von Systemen in Produktionslinien - Gulden, Peter; Fischer, Christian; Lipka, Melanie; Marschall, Albert; Fritzsch, Thomas; Franke, Jörg; Vossiek, Martin (MikroSystemTechnik Kongress 2015 "MEMS, Mikroelektronik, Systeme", Proceedings, 2015)
The continuous tracking of tool positions and transport means is an important factor in terms of efficiency and tracking of safety relevant production steps. The research project NaLoSysPro investigates a novel solution for tracking the assembly tools for screws and nuts at a manual work station. The project targets miniaturization steps like 24 GHz RF chip-design and antenna module integration as well as novel positioning algorithms and individual worker guidance during assembly. A setup consisting of worker information system, work station and wireless positioning system will be realized during the project.
lhft_intern.bib::Lipka15a

Nanojet 3D Printed Coplanar Waveguides on Flexible Polyimide Substrate up to 24 GHz - Lomakin, Konstantin; Ankenbrand, Markus; Sippel, Mark; Franke, Jörg; Helmreich, Klaus; Gold, Gerald (1st IEEE International Conference on Flexible and Printable Sensors and Systems (FLEPS 2019), 2019)
This work proposes an approach for manufacturing of high precision ungrounded coplanar waveguides as high speed interconnections for flexible and wearable sensor as well as IoT systems. Characterization of these printed transmission lines up to a frequency of 24 GHz reveals an insertion loss of up to 8 dB/cm and therefore provides practical advice towards realizable line lengths. Although exhibiting approximately 4 times the attenuation as compared to conventionally manufactured flexible PCB transmission lines, the proposed approach allows for selectively realizing highly precise structures where necessary. Moreover, it is applicable on three-dimensional substrates, such as 3D-MIDs and therefore addresses various future applications.<br

Needle winding for distributed round-wire-windings without the use of insulation disks - Stenzel, P.; Dollinger, P.; Mihajlovic, D.; Richnow, J.; Franke, Jörg; Endisch, C. (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
Automotive traction drives require primarily high degrees of efficiency and high power densities. Therefore one main goal in the production of electric traction drives is the minimization of the end windings. End windings are necessary, however, they do not add to the power transformation and in addition they increase the space and the copper losses. In the serial production of distributed round-wire-windings the insertion technology is mainly used. An alternative to this production method is the needle winding technology. In the recent past several concepts for distributed windings have been developed and published using so called 'end disks' or 'insulation disks' [1], [2], [3], [4]. Insulation disks offer advantages concerning process automation, however, they lead to a considerable increase of the height of the end windings. In order to make the needle winding technology applicable for automotive traction applications this paper presents a new concept for distributed windings without the use of insulation disks.
CRIS-Team Scopus Importer:2023-03-07

Neuartiger Ansatz zur flexiblen Fertigung verlustoptimierter Statorblechpakete - Schneider, Michael; Urban, Nikolaus; Meyer, Alexander Wilhelm; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2017)
Keywords: E|DRIVE

Neue Ansätze für Energiemanagement und Energieeffizienz in der Produktion - Böhm, Ralf; Praß, Julian; Bürner, Johannes; Franke, Jörg (Umwelt-Technologie und Energie in Bayern, 2018)

Neutrophil Extracellular Traps Promote the Development and Growth of Human Salivary Stones - Schapher, Mirco; Koch, Michael; Weidner, Daniela; Scholz, Michael; Wirtz, Stefan; Mahajan, Aparna; Herrmann, Irmgard; Singh, Jeeshan; Knopf, Jasmin; Leppkes, Moritz; Grüneboom, Anika; Alexiou, Christoph; et al. (Cells, 2020)
Salivary gland stones, or sialoliths, are the most common cause of the obstruction of salivary glands. The mechanism behind the formation of sialoliths has been elusive. Symptomatic sialolithiasis has a prevalence of 0.45% in the general population, is characterized by recurrent painful periprandial swelling of the affected gland, and often results in sialadenitis with the need for surgical intervention. Here, we show by the use of immunohistochemistry, immunofluorescence, computed tomography (CT) scans and reconstructions, special dye techniques, bacterial genotyping, and enzyme activity analyses that neutrophil extracellular traps (NETs) initiate the formation and growth of sialoliths in humans. The deposition of neutrophil granulocyte extracellular DNA around small crystals results in the dense aggregation of the latter, and the subsequent mineralization creates alternating layers of dense mineral, which are predominantly calcium salt deposits and DNA. The further agglomeration and appositional growth of these structures promotes the development of macroscopic sialoliths that finally occlude the efferent ducts of the salivary glands, causing clinical symptoms and salivary gland dysfunction. These findings provide an entirely novel insight into the mechanism of sialolithogenesis, in which an immune system-mediated response essentially participates in the physicochemical process of concrement formation and growth.
CRIS-Team Scopus Importer:2020-10-09
Keywords: lithogenesis; neutrophil extracellular traps; neutrophils; salivary glands; salivary stones; sialadenitis; sialolithiasis; stone development; stone growth

New concept for the Integration of Additive Manufactured Mechanical and Mechatronic Components in Aircraft Interior Systems - Gräf, Daniel; Friedlein, Matthias; Gänßmantel, Christopher; Franke, Jörg; Ischdonat, Nils (2020 Advances in Science and Engineering Technology International Conferences (ASET), 2020)

Novel Approach for Implementation of 3D-MID Compatible Functionalities into Computer-Aided Design Tools - Zeitler, Jochen Tobias; Fischer, Christian; Goetze, Bernhard; Franke, Jörg (11th International Congress Molded Interconnect Devices, 2014)
Current Computer-Aided Design (CAD) tools offer a wide scope of functionality for design of mechatronic products. A number of electrical and mechanical CAD tools on the market fulfil demand in almost every application. Prevailing mechanical CAD tools offer besides simple geometric design also many advanced functionalities in the fields of Computer-Aided Engineering (CAE) or Manufacturing (CAM) to create for instance simulations for multi-physics or finite elements besides the simple shape design functionality. Electrical design tools on the other side contain part libraries for the schematic and geometric layout as well as automated routing algorithms with integrated design rule checks. Development within these two design tools often goes ahead simultaneously. However in the field of spatial electronic assemblies like 3D-MID (Moulded Interconnect Devices) a direct integration of the both disciplines is absolutely necessary. A 3D-MID application combines the conventional mechanical design and the electronic layout design on the same application. Therefore, for 3D-MID-design, ECAD (Electronic CAD) systems with the opportunity to create PCB layouts and MCAD (Mechanical CAD) systems with the functionality to design solid shapes have to be integrated into one single development environment. Existing tools allow import of geometrics from MCAD and schematics from ECAD to bring them together in the same environment. Nevertheless some specific functionalities like automated placement of conductor parts or the routing of tracks between them are still unsolved tasks. Due to the time consuming issue of these design domains a solution has to be found. Our research work has the goal to merge the advantages of ECAD and MCAD design instead of developing a completely new software environment. For that approach a layer model was generated, which connects the different software tools to a holistic picture. This should fulfil all requirements in the collaboration of electrical and mechanical design. Also technical restrictions like design and manufacturing rules have to be considered. Due to the nature of 3D-MID not only the electrical functionality is focussed but also the dependence with mechanical conditions. E.g. mechanical contact faces shouldn’t be permitted for electronic part placement or the routing of tracks. In order to realize all these functions a platform independent product model is created and implemented to generate a connection between these different systems and the implicit user knowledge. This product model builds a base for the routing and placement task of 3D-MID and further additional modules that can be implemented into the software structure to improve the scope of functionality. Within the current project that focusses a semi-automated routing, the user will be allowed to rip-up connections between the parts and to reroute with customized conditions by setting waypoints on the carrier surface. The routing will be semi-automated what means that not all connections will be routed at once to allow the user to have several options for the track planning. Finally, future challenges will be evaluated and further use of the results will be discussed in the paper.
Keywords: MID; Design; CAD; Routing

Novel approach for the implementation of 3D-MID compatible routing functionalities into computer-aided design tools - Zeitler, Jochen Tobias; Götze, Bernhard; Fischer, Christian; Franke, Jörg (Advanced Materials Research, 2014)
Molded Interconnect Devices can be considered as attractive option for the integration of electronic functions into mechanical systems. While development methods and procedures reached high standards, CAD tools still drag behind. This paper focusses the necessary software structure for implementing of automated routing algorithms or other MID specific extensions into CAD tools. An innovative three-layer model will be introduced and explained in detail. This paper also describes a method for mapping electrical components on unfolded surfaces for the further implementation of the automated routing algorithms.
CRIS-Team Scopus Importer:2023-03-07
Keywords: 3D-ECAD; Design; Routing; Software development

Novel Ceramic-Based Material for the Applications of Molded Interconnect Devices (3D-MID) Based on Laser Direct Structuring - Bachy, Bassim; Süß-Wolf, Robert; Wang, Li; Fu, Zongwen; Travitzky, Nahum; Greil, Peter; Franke, Jörg (Advanced Engineering Materials, 2018)
Molded interconnect devices (MID) based on laser direct structuring LPKF-LDS® technology are widely used in the realm of electronics. Nowaday, design and development of new materials with improved properties for 3D-MID are in focus. In this work, novel materials based on alumina ceramic with copper oxide additives are developed for this technology. The effect of the sintering temperature and the doping amount of copper oxide on the metallization quality is investigated. Furthermore, the influence of laser process parameters (e.g., laser power, velocity’, and frequency) on process output namely groove dimensions, groove profile, characteristics of structured area, and quality of the final 3D-MID products are discussed. The novel ceramic materials show high flexibility to realize very fine structures. Moreover, the laser-structured and metallized area shows a free edge lap with good quality. After metallization high accuracy with copper line/pitch of 16 μm/20 μm is achieved.
CRIS-Team Scopus Importer:2023-03-07
Keywords: High-Performance Ceramics; Laser Direct Structuring; Molded Interconnect Devices

Novel Concept for a Mechanical Intraurethral Artificial Urinary Sphincter - Preis, Alexander; Treviranus, Johannes; Benke, Elisabeth; Reitelshöfer, Sebastian; Franke, Jörg (Proceedings of the 15th International Joint Conference on Biomedical Engineering Systems and Technologies - BIODEVICES, 2022)
Stress urinary incontinence is a common pathologic condition in society and an increasing socio-economic challenge. Current artificial urinary sphincters for severe cases have high failure rates, cannot be applied sex-independent and their handling is not intuitive. To address these issues, a novel intraurethral closure system was developed. It works without an external energy supply and consists of an inflatable balloon that presses against the inner contour of a surrounding cylindrical structure implanted in the urethra. Regulation of the closure system is achieved by the interaction of the three main components: the closure balloon, the throttle and the compensating reservoir. The developed closing mechanism seals the bladder at rest and during short peak loads and opens only when the bladder pressure is increased by pressing with the abdominals for a longer period of time for micturition.<br
Keywords: Implant; Urinary Incontinence; Stress Incontinence; Artificial Urinary Sphincter; Intraurethral

Novel measurement setup for dielectric elastomer sensors enabling the detection of multiple load scenarios with integrated adjustment for scalable sensor sizes - Martin, Sina; Schieber, Maximilian; Reitelshöfer, Sebastian; Pham, Duc Huy Hoang; Franke, Jörg (Proc. SPIE 11587, Electroactive Polymer Actuators and Devices (EAPAD) XXIII,, 2021)
In healthcare products the proper fit of e.g. orthosis is crucial for its therapeutic success. To monitor movement and pressure, sensors with the ability to adapt their shape to the curvilinear form of the human body as well as a highly dynamic performance during motion are needed. Dielectric elastomer sensors (DES) present most of the required specifications and can be an excellent solution for body-near motion detection. For signal capturing either changes in resistance, capacitance or impedance can be measured. Therefore, different circuit configurations can be used that follow different methods e.g. frequency based or an impedance approach. In this paper, an impedance measurement bridge that enables the detection of stretch and pressure loads with a frequency of 200 Hz is modified. The novel architecture is conceptualized to work with a battery based energy supply and have small enough dimensions to function as a wearable with a wireless communication interface. Furthermore, our former presented additive manufacturing method for dielectric elastomers via aerosol jet printing allows an integrated tuning of the measurement bridge in the process. In addition, to the electrodes of the capacitor one electrode with a defined layer resistance is stacked on top of the DES. Hence, the additional electrode, which makes the architecture scalable for different sensor sizes and shapes, serves as an integrated adjustment of the measurement bridge. The data acquisition of multiple sensors is feasible by time division multiplexing, but is limited in its frequency due to the switching rate of the multiplexer.<br
Keywords: dielectric elastomer sensors; sensing circuit; capacitive; pressure and strain sensors; multiple load; flexible electronics; stretchable sensors; additive manufacturing

Numerical and Experimental Investigation of the Velocity Field in Friction Ventilators - Renz, Andreas; Praß, Julian; Riedel, Jörg; Nadler, Olaf; Becker, Stefan (International Conference on Fan Noise, Aerodynamics, Applications and Systems, 2018)

Numerical Evaluation of Heat Transfer from Rotating Discs Separated by Sealing Elements - Praß, Julian; Reinelt, Mario; Franke, Jörg; Becker, Stefan (Applied Mechanics and Materials, 2017)

Numerical Investigation of a Friction Ventilator for Different Geometrical Setups - Praß, Julian; Renz, Andreas; Franke, Jörg; Weber, Johannes; Becker, Stefan (Advanced Engineering Forum, 2016)

Numerical investigation of the effect of convex transverse curvature and concave grooves on the turbulent boundary layer along a cylinder in axial flow - Wachter, Florian; Metelkin, Alexander; Jovanović, J.; Praß, Julian; Becker, Stefan (International Journal of Heat and Fluid Flow, 2021)
Axisymmetric turbulent boundary layers that develop around streamwise oriented long cylinder-like objects can be found in many applications, such as towed array sonars or marine seismic streamers. In many of these applications, turbulent fluctuations within the boundary layer flow can have a negative impact compared with laminar flow conditions. The aim of the present work is to design a surface modification that influences the turbulent boundary layer around a cylinder in axial flow in order to reduce turbulent fluctuations. To design the surface we consider recent findings regarding the turbulence damping effects of groove-like surface structures and combine these insights with the effect of convex transverse curvature on turbulence. We use large-eddy simulations to investigate the flow around a cylinder of modified design and around a reference circular cylinder. Both flows have a radius-based Reynolds number of Rea≈1.23⋅104" role="presentation">. The modified design leads to a 20 % decrease in the average wall shear stress and results in local reductions in the turbulent intensities, Reynolds stress, the temporal velocity spectrum, and the turbulent dissipation rate. The analysis within the anisotropy-invariant space reveals a tendency towards flow relaminarization. However, the new design has no effect on turbulent pressure fluctuations. We provide suggestions on how to further improve the surface design to achieve even greater flow stabilizatio
CRIS-Team Scopus Importer:2021-10-01
Keywords: Axial cylinder flow; Axisymmetric turbulent boundary layer; Flow control; Seismic streamer; Surface modification; Towed array sonar

Numerical representation of the operating behavior of a cross‐flow friction turbomachine - Praß, Julian; Riedel, Jörg; Renz, Andreas; Franke, Jörg; Becker, Stefan (Chemical Engineering & Technology, 2019)
Based on the tesla‐type turbomachinery principle of operation, a fan consisting of flat, round discs arranged in between two separate channels which generate two air flows in opposite directions are investigated. Simulations of a model with one disc as well as a five‐channel model at different grids were performed. With almost unthrottled operation, secondary flows could be determined at velocity magnitudes of up to 20 % of the mean main flow velocity, with secondary currents reaching up to 50 % in throttled operation. Besides high dissipation and recirculation these secondary currencies are found to be capable of reducing the overall efficiency of the system. Topic of further investigations is thus the potential of increasing efficiency by means of straighteners and geometric adaption
Keywords: Computational Fluid Dynamics; Heat Transfer; Numerical Simulation; Rotating discs; Tesla-type turbomachinery