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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Reliability of lead-free solders for die attach in automotive power modules - Ottinger, Bettina; Holverscheid, Joshua; Konig, Sebastian; Jerichow, Edgar; Lunz, Sebastian; Sprenger, Mario; Muller, Lars; Goth, Christian; Franke, Jörg (Proceedings of the 24th Electronics Packaging Technology Conference, EPTC 2022, 2022)
Four Sn- based solder joint materials SAC305, SnSb5, SnSb10 and PFDS400® were compared conducting active power cycling tests. In addition, the microstructure before and after the power cycling test was analyzed. Intermetallic compounds were detected at all tested solders after the soldering process. The composition and the amount of intermetallic compound (IMC) phases differed between the solders. The PFDS400® solder joint which consisted mostly of Cu6Sn5 intermetallic compound and an intermediate copper layer showed the highest lifetime followed by SnSb5, SnSb10 and SAC305 solder. While SAC305, SnSb5 and SnSb10 failed due to material fatigue, the PFDS400® solder joint did not show any cracks, damage, or delamination.
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Reliability of Mechatronic Integrated Devices Regarding Failure Mechanisms - Bräuer, Philipp; Wurzer, Lukas; Kuhn, Thomas; Knoeller, Andrea; Mueller, Hagen; Eberhardt, Wolfgang; Zimmermann, Andre; Franke, Jörg (2020 43RD INTERNATIONAL SPRING SEMINAR ON ELECTRONICS TECHNOLOGY (ISSE), 2020)
CRIS-Team WoS Importer:2021-02-26

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Simulation of orthocyclic windings using the linear winding technique - Bönig, Jochen; Bickel, Benjamin; Spahr, Michael; Fischer, Christian; Franke, Jörg (5th International Conference on Electric Drives Production, EDPC 2015, 2015)
A continuously rising number of electric vehicle licensing is mentioned since the last few years in Germany. For a cost-efficient production of electrical engines in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby, the prediction of wire behavior is one of the key challenges. Therefore, a detailed model is built to investigate wire behavior during the linear winding process. The finite element based simulation tool LS-DYNA serves as explicit dynamics tool. The tool works with an explicit time integration method for time discretization. To represent the high dynamic process of winding within this simulation, dynamic influences such as rotational speed or acceleration of the coil body are definable. Within process simulation, the given boundary conditions are applied to the model. The non-linear material properties of the wire are validated under scrutiny by a tensile test and by values out of datasheets in previous research work. Simulation results of orthocyclic windings using the linear winding technique are presented within this paper. The dynamic simulation model is validated by experiments using the caster angle of the wire guide as reference parameter. The caster angel rises during the winding process of the first layer until the wire jumps to the next layer. Hence, it is possible to identify the maximum caster angle and match the simulation value against the experiment value. The travel profile of the wire guide is identified as extremely important to generate an orthocyclic winding. Another substantial part is the wire fixation respectively the geometry to support the first winding offset from winding one to winding two. Results of orthocyclic windings are simulated with and without grooves on the coil body surface and demonstrate the positive influence of grooves for an accurate orthocyclic winding picture.
Keywords: Explicit dynamics; linear winding; simulation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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