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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Mechanical modifications of soft actuators for the use as a dynamic iris implant - Martin, Sina; Schwab, Jürgen; Caballero Lopez, Patricio; Benke, Elisabeth; Reitelshöfer, Sebastian; Franke, Jörg (43rd Annual International Conference of the IEEE Engineering in Medicine & Biology Society (EMBC), 2021)
Aniridia is a condition characterized by defects or absence of the iris. Since the eyes are a central point of attention in the human face, these deformities are often covered with cosmetic implants. However, patients suffer from the static pupil diameter of these implants, resulting in high light sensitivity or inadequate night vision. Therefore, we present a functional iris implant based on dielectric elastomer actuators. These electric drives are characterized by a silent and continuous adaptation as well as a small construction volume and a low heat emission. Since they normally exhibit in-plane uniaxial motion, this displacement must be focused to operate similarly to the iris sphincter. Therefore, we investigated possible mechanical modifications of the setups to generate a directional motion. The results of the study are presented and discussed.Clinical Relevance- The proposed system design enables the functional treatment of aniridia and other accidental iris defects. In addition, the system serves as a basis for later developments of e.g. functional lenses that allow focus adjustment.
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Mechanical qualification and microstructural analysis of alumina produced by material extrusion - Utsch, Daniel; Bründl, Patrick; Franke, Jörg; Erdogan, Hüseyin (Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 2023)
Ceramics with their advantageous properties such as high thermal conductivity and electrical insulation are attractive to circuit carrier materials in electronics production. Using material extrusion (MEX-AM) for reasons of flexible manufacturing, this work produces green bodies with low surface roughness, which is necessary for subsequent metalizing to create 3D circuit carriers. Systematic variation of post-treatment profiles (debinding, sintering) leads to different microstructures and thus influences mechanical properties. A comprehensive mechanical qualification of ceramic samples produced with MEX-AM and post-treated differently has been carried out, in which tensile, compressive and flexural strength are analyzed. Using the Anderson Darling Test, it is shown that statistical methods standardized for conventional ceramics are applicable to additively manufactured specimens. A mean bending fracture strength comparable to conventional ceramics could be achieved combining a low heating rate profile for debinding with a two-step sintering (TSS) approach, which resulted in reduction of grain size, as SEM analysis confirmed.<br

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

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

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

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

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

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

Methodik zur monetären Bewertung von Serviceplattformen - Eine systematische Analyse von Plattforminteraktionen - Hartner, Fabian; Kerker, Sebastian; Bodendorf, Frank; Kirchner, Markus; Uebler, Moritz; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2021)
In order to be able to implement industrial services independent of time and location, digital, data-based services are increasingly being offered on online platforms. This article presents a methodology for the monetary valuation of different functionalities of service platforms, which also includes additional platform-specific effects, such as value co-creation. Users of the methodology receive a calculation tool that considers not only savings for the platform operator in interactions but also the added value for the customer.
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Methodology for digital planning and virtual validation of retroactively automated assembly systems - Metzner, Maximilian; Barth, Fabienne; Bönig, Jochen; Franke, Jörg (Tagungsband des 4. Kongresses Montage Handhabung Industrieroboter, 2019)
Disruptive technologies such as lightweight robots, autonomous mobile robots as well as powerful sensor and control technologies enable flexible and economical automation of production processes. Therefore, they are suitable for retroactive automation of existing systems. During retrofit, the conversion or commissioning time is a critical factor, which is why exact planning and virtual validation are necessary. Novel, digital tools offer extensive assistance for this task. This article describes a systematic and application-oriented methodology for continuous digital planning and validation of these automation solutions up to a turnkey robotic automation system. A validation of the proposed methodology in an electronics production scenario is describe
Keywords: Adaption Planning; Robot Simulation; Factory Automation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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