2-D Fluid Simulation Approach for Miniwave Soldering - Seidel, Reinhardt; Sippel, Marcel; Franke, Jörg (IEEE, 2022)
Design reviews are a key bottleneck of fast product development processes. In order to judge manufacturability, reliable models of the design and the manufacturing process are essential. This paper presents a 2-D fluid simulation model as a manufacturability check for lead free mini wave soldering and evaluates it against soldering experiments. Miniwave soldering is a widely applied process to automatically solder THT-components onto mixed SMT/THT circuit board assemblies. The vertical hole fill is the acceptability criterion defined by the IPC-A610 and depends on the copper layer design of the THT solder joints due to thermal diffusion during the soldering process. With increasing copper content in high performance multilayer PCBs, the thermal diffusion increases likewise and causes significant soldering problems with respect to insufficient hole fill. To mitigate the design reviews as critical bottleneck for the time to market, in this paper a numerical 2-d model is implemented in ANSYS Fluent to predict hole fill of potential critical solder joints and validate the model against respective soldering experiments. The parametrized copper layer design of the solder joints are automatically generated by a python script, meshed and solved in ANSYS Fluent. This allows easy configuration of different copper layer designs with respect to board thickness, layer count and thickness as well as pin and hole diameter, solder nozzle diameter and the relevant soldering parameters. Temperaturedependent material models of the solder alloys to describe density, viscosity and wetting angle are derived from literature and applied to the simulation model. The simulation methodology is divided in two steps, first the flow field of the solder fontain has to be calculated. In the second step, the soldering process can be simulated based on the stable flow field including capillary action, heat and mass transfer based on the volume of fluid method. The simulation results show good agreement with soldering experiments. With this developed and validated simulation method the understanding of heat transfer and fluid mechanical effects during miniwave soldering can be improved.<br
Keywords: Fontain soldering; selective wave; barrel fill; solder joint design; design for manufacturing; through hole technology; lead-free

3D-Opto-MID for asymmetric optical bus couplers - Lorenz, Lukas; Hanesch, Florian; Nieweglowski, Krzysztof; Eiche, Yannic; Franke, Jörg; Hoffmann, Gerd Albert; Overmeyer, Ludger; Bock, Karlheinz (Proceedings - 2020 IEEE 8th Electronics System-Integration Technology Conference, ESTC 2020, 2020)
The development of easy-to-use optical bus-systems without the need for waveguide interruption is one important step to establish optical interconnects in short- to midrange networks. The challenge from the packaging side of view is the three-dimensional integration of optical parts and waveguides to a novel kind of package, called 3D-Opto-MID. In this article, we present an approach for stereolithographic printed, three-dimensional polymer structures on ceramic thick-film substrates. Thus, we are able to combine the design freedom of 3D printing with the excellent RF- and heat-management properties of the thick-film technology, especially important for electro-optical (e/o) converters. On the three-dimensional structures, the waveguides for the bus-coupler are applied, while the ceramic holds the electro optical converters. Furthermore, the 3D printing allows for easily manufactured alignment- and fixing structures for the coupler with a high accuracy. The results section shows the analysis of the adhesion behavior of the printed polymer on the ceramic, as well as the obtainable tolerances with the printed alignment structures. The average accuracy of the alignment was measured with 31.1µm, which is sufficient for the used 200 µm multimode waveguides. Furthermore, we demonstrate the functionality of the optical path of the module assembly, as well as the coupling to a bus waveguide, which proves the success of the 3D-Opto-MID integration.
CRIS-Team Scopus Importer:2020-12-04
Keywords: 3D-MID; 3D-packaging; Additive manufacturing; Ceramic polymer hybrid package; Optical bus coupling; Stereo lithography

3D-Printed Bowtie Filter Created by High Precision NanoJet System Combined with Novel Printing Strategy - Sippel, Mark; Lomakin, Konstantin; Ankenbrand, Markus; Petersen, Matthias; Franke, Jörg; Helmreich, Klaus; Vossiek, Martin; Gold, Gerald (28th Conference on Electrical Performance of Electronic Packages and Systems (EPEPS 2019), 2019)
This paper focuses on the latest aerosol based printing system in conjunction with a newly developed manufacturing method. The presented novel method is successfully demonstrated on a Bowtie Filter in comparison to the same pho-tolithographically produced structure.<br

3D Printed Helix Antenna - Lomakin, Konstantin; Pavlenko, Tatiana; Sippel, Mark; Gold, Gerald; Weidner, T; Helmreich, Klaus; Ankenbrand, Markus; Franke, Jörg (European Conference on Antennas and Propagation (EUCAP), 2018)

3D printing for sizing left atrial appendage closure device: head-to-head comparison with computed tomography and transoesophageal echocardiography. - Hell, Michaela M.; Yoo, In Seong; Achenbach, Stephan; Franke, Jörg; Blachutzik, Florian; Röther, Jens; Graf, Verena; Raaz-Schrauder, Dorette; Marwan, Mohamed; Schlundt, Christian (EuroIntervention, 2017)
AIMS Device sizing for LAA closure using transoesophageal echocardiography (TEE) can be challenging due to complex LAA anatomy. We investigated whether the use of 3D-printed left atrial appendage (LAA) models based on preprocedural computed tomography (CT) permits accurate device sizing. METHODS AND RESULTS Twenty-two (22) patients (73±8 years, 55% male) with atrial fibrillation requiring anticoagulation at high bleeding risk underwent LAA closure (WATCHMAN device). Preprocedurally, LAA was sized by TEE and third-generation dual-source CT. Based on CT, 3D printing models of LAA anatomy were created for simulation of device implantation. Device compression was assessed in a CT scan of the 3D model with the implanted device. Implantation was successful in all patients. Mean LAA ostium diameter based on TEE was 22±4 mm and based on CT 25±3 mm (p=0.014). Predicted device size based on simulated implantation in the 3D model was equal to the device finally implanted in 21/22 patients (95%). TEE would have undersized the device in 10/22 patients (45%). Device compression determined in the 3D-CT model corresponded closely with compression upon implantation (16±3% vs. 18±5%, r=0.622, p=0.003). CONCLUSIONS Patient-specific CT-based 3D printing models may assist device selection and prediction of device compression in the context of interventional LAA closur

3D Scanning of Workpieces with Cooperative Industrial Robot Arms - Wagner, Maximilian; Heß, Peter; Reitelshöfer, Sebastian; Franke, Jörg (Proceedings of ISR 2016: 47st International Symposium on Robotics, 2016)
This paper describes the realization of a cooperative scanning approach by two industrial robot arms. The basic idea is the distribution of the movements on two robots by one robot handling the sensor and the other one handling the workpiece. Through this approach reachability is improved. In addition, the reference between the workpiece and the grasping robot is included in the scan model. Thus, the resulting model can be used well for subsequent workpiece related machining processes.

3D-Sensorsystem für den kollisionsfreien Betrieb flexibler Strahlentherapiegeräte - Buschhaus, Arnd; Franke, Jörg; Reitelshöfer, Sebastian; Ziegler, Christian; Röttenbacher, Maren (Internationales Forum Mechatronik 2013, 2013)
Ein bedeutendes Mittel zur Behandlung von Tumoren stellt ionisierende Strahlung dar. Neben der Verwendung einer geeigneten Strahlquelle kommt dabei vor allem der Bestrahlungsdosis zur Tumorbehandlung während der Therapieablaufs eine bedeutende Rolle zu. Ziel dieser Behandlungsmethoden ist es, die Belastung des umliegenden Gewebes zu reduzieren und die zeitliche Dauer möglichst kurz zu gestalten. Moderne Therapiegeräte ermöglichen hierzu eine Anpassung der Bestrahlungsrichtung bezüglich des Tumors. Der Strahlenaustritt am Gerät wird dabei auf einer kreisförmigen Bahn um den Tumor bewegt, der sich im Isozentrum der Bestrahlung befindet. Zur flexiblen Behandlung von Tumoren besteht zunehmend die Forderung nach einer Erhöhung der kinematischen Freiheitsgrade des bestrahlenden Gerätes. Einen wesentlichen Einfluss auf die Therapiedauer hat derzeit die notwendige geringe Geschwindigkeit der Kinematik, mit welcher diese zwischen den verschiedenen Bestrahlpositionen bewegt wird. Eine geringe Geschwindigkeit ist erforderlich, um Kollisionen des Patienten mit der Kinematik zu vermeiden und Verletzungen zu verhindern. Aus dieser Forderung ergibt sich ein ungünstiges Verhältnis von den Positionierzeiten des Gerätes zu den Bestrahlzeiten. Dies führt durch die längere Therapiedauer zu einer zusätzlichen Belastung für den Patienten und zu einer schlechteren Auslastung der investitionsintensiven Therapiegeräte. Durch eine zuverlässige Detektion und Positionsbestimmung des Patienten während der Behandlung und das Ableiten geeigneter Reaktionsstrategien ist es möglich die zulässigen Geschwindigkeiten der Therapiegerätekinematik zu erhöhen und somit die Nebenzeiten signifikant zu reduzieren. Um dies zu ermöglichen ist jedoch eine robuste Erkennung des Patienten und potentieller Kollisionen notwendig. In der Medizintechnik und auch der Strahlentherapie werden mittlerweile zunehmend 3D-Kamerasysteme verwendet, die bei der hochgenauen Patientenpositionierung oder der Atemverfolgung eingesetzt werden. Diese Kamerasysteme qualifizieren sich ebenfalls zur behandlungsbegleitenden überwachung des Patienten um Bewegungen zu erkennen. Hierzu ist jedoch eine robuste Verarbeitung der Kameradaten wesentlich. So müssen anfangs fehlerhafte Bildinformationen durch eine geeignete Filterung eliminiert werden. Eine sich anschließende Erkennung des Patienten muss im Weiteren mehreren Anforderungen genügen: So sind Patienten unterschiedlicher Physiognomie zu erkennen, die Lage des Patienten zur Kamera ist per se nicht bekannt und die Position der Patientenliege ist variabel. Die Patientenerkennung wird über einen Algorithmus realisiert, der die räumlichen Lageinformationen der 3D-Kamera verwendet und über den zusammenhängende Regionen bestimmt werden. Die dem Patienten zugewiesenen Bildpunkte werden im Anschluss binärisiert und im Nachgang die Kanten des Binärbildes bereinigt sowie isolierte Bildbereiche beseitigt. Anschließend wird aus den Bildinformationen ein Skelett des Patienten extrahiert. Diese Körperstruktur wird im Weiteren durch Gelenke erweitert, um z. B. eine Unterscheidung der Gliedmaßen zu ermöglichen und deren Winkelstellungen zu ermitteln. Unter Zuhilfenahme dieser Informationen werden im Nachgang Hüllkörper zur Beschreibung des Patienten erzeugt. Basierend auf einem Bestrahlungsplan werden bei der Behandlung die Stellungen des Therapiegeräts und der Kinematik sowie die optimalen Bahntrajektorien zwischen den Bestrahlpositionen generiert. Während der Durchführung der Bewegungsprogramme wird die aktuelle Stellung des Strahlentherapiegeräts auf Kollisionen mit dem Patienten überprüft. Diese erfolgt über eine Durchdringungsanalyse der Hüllkörperrepräsentation des Patienten und einer geometrischen Repräsentation der Kinematik und des Strahlentherapiegeräts. Die zuverlässige Erkennung des Patienten bei den üblichen Körperhaltungen durch die dargestellten Bildverarbeitungsroutinen konnte im Rahmen der Arbeiten experimentell nachgewiesen werden. Potentielle Gefahrensituationen wurden zuverlässig vom Softwaresystem erkannt und resultieren in einem Stopp der Kinematik.
Keywords: - Robotik - 3D Bildverarbeitung - Strahlentherapie - Kollisionsanalyse - Regelung; 3D-Kameras; B|Mech; Industrieroboter-Assistenzsystem; PMD-Kamera; Roboter

6DoF Pose-Estimation Pipeline for Texture-less Industrial Components in Bin Picking Applications - Blank, Andreas; Hiller, Markus; Zhang, Siyi; Leser, Alexander; Metzner, Maximilian; Lieret, Markus; Thielecke, Jörn; Franke, Jörg (Conference Proceedings, 2019)
Over the next few years, autonomous robots and functionalities are expected to gain increased importance for the shop floor. Perception and the derivation of autonomous behavior is of crucial importance in this context. We present a combined object recognition and pose estimation pipeline to generate pose estimates with six degrees of freedom (6DoF) for bin picking, specifically targeting the suitability for challenging scenarios with texture-less, metallic parts in industrial environments. The pipeline is based on open source algorithms, combining Convolutional Neural Networks (CNNs) and feature-matching methods to create an effective 6DoF pose estimate. We evaluate our approach on several industrial components using a articulated arm robot to guarantee a high level of comparability during the different measurement runs. We further quantify the results using known error metrics for pose estimation, compare the results to established approaches and provide statistical insight into the achieved outcomes to assess the robustness and reliability.<br
Keywords: Pose Estimation; Bin Picking; Mobile Robots

Abschlussbericht: FORobotics - mobile ad-hoc kooperierende Roboterteams, Aktenzeichen AZ-1225-16, Förderzeitraum 1.1.2017-30.6.2020, Berichtszeitraum: 1.1.2017-30.6.2020 - Berger, Julia; Colceriu, Christian; Blank, Andreas; Franke, Jörg; Härdtlein, Christian; Hellig, Tobias; Henrich, Dominik; Heuss, Lisa; Hiller, Markus; Krä, Michaela; Leichtmann, Benedikt; Lottermoser, Albrecht; et al. (2021)
Keywords: FORobotic; Robotic Process Automation; Mobiler Roboter; Mensch-Roboter-Kollaboration

Accelerated aerosol-jet-printing of stretchable rGO-electrodes for stacked dielectric elastomers by using a new hybrid atomizer - Reitelshöfer, Sebastian; Martin, Sina; Nendel, Florian; Schäfer, Thomas; Pham, Duc Huy Hoang; Franke, Jörg (Proceedings of SPIE - The International Society for Optical Engineering, 2020)
The efficient manufacturing of dielectric layers and electrodes for dielectric elastomers is challenging especially for stacked configurations. In an earlier publication we describe a contactless programmable manufacturing approach for aerosol-jet-printing stacked silicone and reduced graphene oxide (rGO)-layers in one process device. One limitation of the setup presented there is the long production time of e.g. 45 minutes for a 1 cm2 electrode with a sheet resistance of 1 Mω. This contradicts the goal of printing numerous layers for stacked systems and is related to the usage of an ultrasonic atomizer. Therefore we present a new hybrid atomizer, which significantly lowers the printing times of rGO-electrodes. This hybrid atomizer again uses an ultrasonic aerosol generation system. Hence, particle-inks without chemical stabilizers that would affect the curing process of printed adjacent silicone structures, can still be used in the system over hours without agglomeration. In addition, a pneumatic aerosol generation is integrated with the new hybrid atomizer. The combined material output of the pneumatic and the ultrasonic approach allows for the printing of rGO-electrodes in two minutes or less with characteristics comparable to those described above. Furthermore, a light-heating-system is integrated into the printing system which enables the fast evaporation of the solvents independently of the height of the previously stacked layers. For this new system, several printing strategies are evaluated by comparing different programmed trajectories of the print head. Printed rGO-electrodes with thicknesses from 3-20 μm and values for the sheet resistance from 1 MOhm to 200 kOhm are characterized regarding their ability to bear a maximal deformation up to 100 % and repeated cyclic stretching up to 25 %.
CRIS-Team Scopus Importer:2020-06-05
Keywords: aerosol-jet-printing; hybrid atomizer; rGO-electrodes; stacked dielectric elastomers

Accelerated Production Ramp-Up Utilising Clustering and Visualisation of Process Chain Interrelationships - Meiners, Moritz; Mayr, Andreas; Lechler, Tobias; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Accuracy Analysis and Improvement for Cooperative Industrial Robots - Buschhaus, Arnd; Wagner, Maximilian; Franke, Jörg; Reitelshöfer, Sebastian; Heß, Peter (Proceedings of the 14th International Conference on Informatics in Control, Automation and Robotics, 2017)

Accuracy and immersion improvement of hybrid motion capture based real time virtual validation - Bönig, Jochen; Fischer, Christian; Weckend, Holger; Döbereiner, Florian; Franke, Jörg (Procedia CIRP, 2014)
Using a digital human model for dynamic analysis is due to the high modelling complexity in digital environments not very prevalent. The movement of the worker is either unrealistic, or time-consuming to realize. Therefore, the need for research is a time saving possibility to explore virtual validation by a human model taking advantage of a nonetheless realistic movement design. To achieve this goal, we use an experimental setup including both a hybrid motion capture system and an interface for the connection to digital validation software. The motion capturing in connection along with the validation software allows real time modelling respectively tracking and therefore a realistic movement of the human model. To get good results while applying the motion capturing approach in mixed reality situations, it is necessary to have an exact registration between the real and virtual environment. Hence, the experimental setup must be designed for both. The key challenge here is to superimpose the CAD data with the real objects used for haptic feedback and better immersion. To realize an optimal registration we use a laser tracker solution.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Assembly; Mixed reality; Simulation

A Comprehensive Study on the Automation Potentials and Complexities of Advanced and Alternative Die-Attach Technologies for Power Electronic Applications - Syed Khaja, Aarief Hussain; Kästle, Christopher; Müller, Martin; Franke, Jörg (Applied Mechanics and Materials, 2015)
The field of power electronics packaging presents intricate and interdisciplinary challenges. System costs, reliability and performance are strongly determined by various aspects such as mechanical design, materials, thermal management and interconnect technologies. The overall costs of the product depend mainly on the complete process chain in the module development. Automation as well plays an important role and facilitates higher production rates, efficient use of materials, better product quality, and reduced factory lead times. This paper focuses on emerging interconnection technologies of bonding semiconductor components to power electronic substrates like diffusion soldering, conductive adhesive bonding and reactive multi-layer bonding. An overview on the automation potentials and complexities in individual technologies for the manufacturing of reliable and cost-effective power modules is given and discussed. Thus, a basis is created for choosing optimal die-attach technology depending on economic and technologic demand by comparing the state-of-the-art and advanced technologies.
Keywords: automation; manufacturing process; power electronics packaging

A Concept for Context Awareness in SmartEnvironments - Bauer, Jochen; Wittenberg, Thomas; Waldhör, Klemens; Hechtel, Michael; Holzwarth, Martin; Seßner, Julian; Ristok, Bruno; Böhle, Florian; Schena, Annamaria; Falanga, Annarita; Franke, Jörg (Current Directions in Biomedical Engineering, 2020)
All aspects of daily life increasingly include digiti-zation. So-called „smart home“ technologies, as well as „wear-ables“, are gaining attention from more and more dwellers.Therefore, sensor-based, individualized, AI-based services forimproved post-intervention monitoring and therapy accompa-niment will become feasible and possible if these systems offera related context-awareness. This paper provides an approachon how to sense and interpret specific contexts with the helpof wearables, smartwatches, smart home sensors, and emotiondetection softwar
Keywords: emotion recognition; smart home; smart living; smartwatches; wearables

A Concept for Wireless Network Integration in Production System Planning - Vukovic, Petar; Lechler, Tobias; Franke, Jörg (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2020)
In the context of Industry 4.0, the flexibility of production systems rises constantly. To fulfil this demand, wireless instead of classic wired communication networks can be used. This trend is supported by the advancement of new network standards such as 5G. Current design of wireless networks in production systems in the early planning phase relies on best practices and experience. In following planning phases worst case calculations are used to verify the network topology. Taking the dynamic behaviour of flexible production systems into account, networks are constantly changing. In this paper, existing discrete event simulation of production systems is augmented with planning components of wireless networks to allow a more precise planning of production systems using wireless communication.
CRIS-Team Scopus Importer:2020-10-30
Keywords: 5G; discrete event simulation; production system planning; wireless networks

A Conceptional Study towards Developing a Novel Copper Top-Side Interconnection Process in Power Electronics using Additive Manufacturing - Ockel, Manuela; Sippel, Marcel; Hecht, Christoph; Janisch, Lucas; Franke, Jörg (2023)

Active controllable and flexible winding needle an option to reduce the complexity of needle winding machines and the stress on enameled wire - Schneider, Michael; Bickel, Benjamin; Risch, Florian; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
State of the art needle winding technologies have one thing in common-a stiff, straight or bent winding needle. During the manufacturing process of electrical machines, the used enameled wires are exposed to deformations which decrease the insulation resistance against partial discharge and disruptive discharge. A reduced insulation resistance shortens the product lifecycle. The active controllable and flexible winding needle is able to adapt its form to the mechanical behavior of wire during any deformation and thus to wind wires more gently. In the production of electrical machines the copper filling factor in the slot is often considered key. To provide the needed space for the tools to move through the stator while distributing the windings, the winding tools have to be rather small or the inner diameter of the stator has a minimum whereat the feasibility for needle winding is still present. With the actively controllable and flexible winding needle no more extra axis and other constructions are necessary to fulfill the requirements of a small tool at maximum flexibility.
CRIS-Team Scopus Importer:2023-03-07
Keywords: distributed winding; winding guide nozzle; winding needle; winding technology

Active Wind Turbine Deicing-Systems Produced via Plasma-Coating Technology - Braun, Thomas; Weber, Johannes; Brüstle, Maximilian; Wössner, Peer; Praß, Julian; Franke, Jörg (Advanced Materials Research, 2016)

Adapted pricing scheme for the integration of vehicle-to-grid into the energy system - Teske, Franz; Fehrle, Adrian; Praß, Julian; Franke, Jörg (11th International Electric Drives Production Conference (EDPC), 2021)
Temporarily high electricity demand resulting from simultaneous charging of many electric vehicles (EVs) require massive expansion of the future grid infrastructure. Using EVs in a way that serves the power system in such by contributing to peak shaving, valley filling, and flattening the load curve of the grid would help to reduce the cost of grid expansion. Based on the current market design, grid-serving bidirectional charging of EVs is still uneconomical for the EVs owners in Germany since it is burdened with various levies, taxes, and fees. We propose an adapted pricing scheme for bidirectional charging that incentivizes a system-serving behavior. For this purpose, we develop a mixed-integer linear optimization model that considers different types of electricity use in the EVs. Based on a simulation, we show that bidirectional charging can generate significant profits under the condition that the system-serving electricity quantities are billed without levies, taxes, and fees or if the EVs are treated like other storage units operating on the electricity market. The analysis shows that bidirectional grid interactions are particularly worthwhile for parking situations at residential properties, especially with long parking times on weekends, high electricity consumption and when taking advantage of volatile intraday prices.<br
Keywords: electric vehicle; linear programming; pricing; charging and discharging schedule; vehicle to grid

Adaption of the ultrasonic welding technique to the process of joining insulated copper wires with standardized tubular cable lugs - Spreng, Simon; Glassel, Tobias; Franke, Jörg (Electrical Contacts, Proceedings of the Annual Holm Conference on Electrical Contacts, 2015)
Within the manufacturing of electric drives, the joining of resin insulated copper wires with standardized tubular cable lugs has to be seen as an important manufacturing step, as this process is one major reason for drive malfunctions - especially in case of mobile devices. Currently, the thermo-crimping technique is commonly used, because it combines high process stability with short tact times. However, the thermo-crimping tools show strong wearing within short periods, as the required heat to skin the insulated copper wires has to be supplied from the electrodes themselves. Therefore, the electrode materials have to face simultaneously high pressures and temperatures up to 650°C, resulting in highly frequent setup processes and corresponding costs. For this reason, a new technique to join insulated copper wires with cable lugs, based on the ultrasonic welding procedure, was investigated at the department FAPS. The following paper describes the explored results regarding the technique of ultrasonic welding. Hereby, the new technology is compared with the thermo-crimping process concerning the joint quality, tact time and tool wearing.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric drives manufacturing; thermo crimping; ultrasonic crimping

Adaptive Motion Control Middleware for Teleoperation Based on Pose Tracking and Trajectory Planning - Blank, Andreas; Karlidag, Engin; Zikeli, Georg; Metzner, Maximilian; Franke, Jörg (Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021, 2021)
Concurrent with autonomous robots, teleoperation gains importance in industrial applications. This includes human-robot cooperation during complex or harmful operations and remote intervention. A key role in teleoperation is the ability to translate operator inputs to robot movements. Therefore, providing different motion control types is a decisive aspect due to the variety of tasks to be expected. For a wide range of use-cases, a high degree of interoperability to a variety of robot systems is required. In addition, the control input should support up-to-date Human Machine Interfaces. To address the existing challenges, we present a middleware for teleoperation of industrial robots, which is adaptive regarding motion control types. Thereby the middleware relies on an open-source, robot meta-operating system and a standardized communication. Evaluation is performed within defined tasks utilizing different articulated robots, whereby performance and determinacy are quantified. An implementation sample of the method is available on: https://github.com/FAU-FAPS/adaptive_motion_control.<br
Keywords: Industrial Robots; Teleoperation; Motion Control

Adaptive Optimal Multiple Object Tracking Based on Global Cameras for a Decentralized Autonomous Transport System - Zhang, Xu; Scholz, Michael; Paryanto, Paryanto; Franke, Jörg (Applied Mechanics and Materials (Volume 840), 2016)

A Dataset of Electrical Components for Mesh Segmentation and Computational Geometry Research - Scheffler, Benedikt; Bründl, Patrick; Nguyen, Huong Giang; Stoidner, Micha; Franke, Jörg (Scientific Data, 2024)
Data quality is of crucial importance in the field of automated or digitally assisted assembly. This paper presents a comprehensive data set of triangle meshes representing electrical and electronic components obtained by scraping Computer Aided Design (CAD) models from the Internet. Consisting of a total of 234 triangle meshes with labelled vertices, this data set was specifically created for segmentation tasks. Its versatility for multimodal tasks is underscored by the presence of various labels, including vertex labels, categories, and subcategories. This paper presents the data set and provides a thorough statistical analysis, including measures of shape, size, distribution, and inter-rater reliability. In addition, the paper suggests several approaches for using the data set, considering its multimodal characteristics. The data set and related findings presented in this paper are intended to encourage further research and advancement in the field of manufacturing automation, specifically spatial assembly.<br
Keywords: Electrical and electronic engineering; Mechanical engineering; Scientific data

Additive Copper Metallization of Semiconductors for Enabling a Copper Wire Bonding Process - Hensel, Alexander; Müller, Martin; Kohlmann-von Platen, Klaus; Franke, Jörg (Proceedings of 40th International Spring Seminar on Electronics Technology (ISSE), 2017)
Current societal and political trends such as climate protection have brought demands and regulations for ever-increasing efficiency in energy applications. The decentralized supply of energy and the integration of regenerative energy sources are also demands which concern both politics and society as well as industry. Especially the electronics industry with power electronics is developing rapidly under these trends and always finds new fields of application. Here, power modules function as a link between energy sources and energy consumers. Consequently, high demands are placed on an efficient assembly and connection technology of future power electronics modules. Current technologies, such as wire bonding, have limitations in terms of compact design and thermal management, thereby focusing on improved interconnect technologies and materials. In the framework of this paper, a plasma- based coating process for the additive copper coating of semiconductors in order to enable a copper wire bonding process is presented.
Keywords: Power electronics; additive manufacturing; interconnection technology; copper wire bonding

Additive Fertigung in der Hochfrequenztechnik – Potenziale und Herausforderungen - Lomakin, Konstantin; Sippel, Mark; Gold, Gerald; Rochholz, P; Helmreich, Klaus; Ankenbrand, Markus; Gräf, Daniel; Franke, Jörg (PLUS - Produktion von Leiterplatten und Systemen, 2017)

Additive Manufacturing of 3D Circuit Carriers with Improved Thermal Conductivity - Utsch, Daniel; Piechulek, Niklas; Franke, Jörg (45th International Spring Seminar on Electronics Technology (ISSE), 2022)
The ongoing demand for more powerful electronic assemblies requires the development of more flexible systems with substrates showing improved thermal and electrical properties. In this regard, fiber-filled polymers processed by Additive Manufacturing technologies are promising. While previous work rather focuses on the material and mechanical aspects of filled polymers and 3D printing, this work proposes an innovative approach to manufacture electronic assemblies additively using Fused Filament Fabrication with glass fiber-filled polymers to create 3D substrates and using digital printing technologies to create electrically conductive structures on the manufactured specimens. For this reason, a reduction of substrate surface roughness through systematic optimization of parameter configuration is necessary to print constant conductive lines subsequently. By this means, 3D circuit carriers for electronic assemblies with improved thermal conductivity can be produced completely additively. Surface roughness of Ra=2.6μm and Rz=42.0μm was achieved in this work, and the printed lines were qualified in optical, electrical, and mechanical regard.<br

Additive manufacturing of 3D-copper-metallizations on alumina by means of selective laser melting for power electronic applications - Stoll, Thomas; Kirstein, Matthias; Franke, Jörg (CIPS 2018 - 10th International Conference on Integrated Power Electronics Systems, 2018)
In the power electronic sector thick metallizations of the substrates are required to ensure high current carrying capabilities. In order to guarantee an optimal thermal dissipation, ceramic substrates are state of the art and commonly used. In general, LTCC, HTCC, DBC or AMB technologies are used for fabricating circuit carriers in firing processes for power electronic applications. Those technologies however need subsequent process steps like structuring, etching and washing that are cost intensive and have a negative environmental impact. Moreover, the flexibility of those technologies for prototyping, small-batch productions and special requirements is limited. In this context Additive Manufacturing (AM) can provide a solution for those constraints. This study reveals the benefits of the generative manufacturing process such as material efficiency, product customization/–flexibility, elimination of the usage of tools, constructional freedom and less process steps in contrast to the conventional fabrication methods of ceramic substrates. The present paper illustrates further investigations in manufacturing thick copper structures (700 µm) on alumina with the usage of the Selective Laser Melting (SLM) technology. Observable delaminations due to high tensions within the selective laser melted metallization could be eliminated by heating the build platform up to a substrate temperature of 250 °C and a reduction of residual oxygen in the process chamber to 5 ppm. As a final demonstrator, 3D-structures like load connections and bridges on 750 µm thick SLM-copper-metallizations on alumina, free of delaminations and oxidations could be manufactured.
CRIS-Team Scopus Importer:2023-03-07

Additive Manufacturing of 3D-copper-metallizations on Alumina by means of Selective Laser Melting for Power Electronic Applications - Stoll, Thomas; Kirstein, Matthias; Franke, Jörg (CIPS 2018 10th International Conference on Integrated Power Electronic Systems, 2018)

Additive Manufacturing of an Electric Drive - A Feasibility Study - Urban, Nikolaus; Meyer, Alexander Wilhelm; Jeckel, Moritz; Leder, Michael; Franke, Jörg (2018 International Symposium on Power Electronics, Electrical Drives, Automation and Motion (SPEEDAM), 2018)
Additive manufacturing (AM) of end-use products is becoming more important to a variety of different industry sectors. Increasingly, more companies are utilizing the specific characteristics such as lightweight construction potential, functional integration and cost advantages in the area of small quantities for their production. Up to now, the additive manufactured components fulfil their function mainly by their geometric form. In order to elevate AM to the next level of functionality, it is necessary to directly generate mechatronised products and integrate electrical, thermal, magnetic or cognitive capabilities directly during production. In this publication we demonstrate that this is already partly possible by means of a nearly completely additive manufactured small electric motor.
Keywords: Additive Manufacturing; Electric Drive; Laser Beam Melting; Soft Magnetic Printing; SLM

Additive Manufacturing of Coplanar Transmission Lines on Alumina Substrate up to 24 GHz using Laser Assisted Selective Metallization - Lomakin, Konstantin; Wang, Li; Job, Alexander; Süß-Wolf, Robert; Franke, Jörg; Helmreich, Klaus; Gold, Gerald (2020 50th European Microwave Conference (EuMC), 2021)
This work proposes a novel approach for fabrication of high precision radio frequency circuits on low loss ceramic substrates by an additive manufacturing laser assisted selective metalization process. Coplanar waveguides are realized and measured with a GSG probe setup revealing an attenuation coefficient of approximately 110dB/m at 24 GHz, hence suggesting feasibility of the proposed approach. The simplicity of the process makes it an auspicious candidate for development of future communication and sensor applications due to the combination of high performance substrates and simple fabrication technique, while the required precision for mmWave range and above may be achieved by improving the optical laser system and metal platin

Additive Manufacturing of Neodymium-Iron-Boron Permanent Magnets - Urban, Nikolaus; Kühl, Alexander; Glauche, Markus; Franke, Jörg (2018 8th International Electric Drives Production Conference (EDPC), 2018)
Keywords: Magnetic hysteresis; Magnetic properties; Powders; Perpendicular magnetic anisotropy; Additives; Metals; Additive Manufacturing; Rare Earth Magnet; NdFeB; Printed Magnet; Net Shape Magnet

Additive Manufacturing Technologies for Functionalized Mechatronic Integrated Devices - Franke, Jörg; Spahr, Michael; Kuhn, Thomas; Hörber, Johannes (11th International Congress Molded Interconnect Devices, 2014)
Keywords: E|DRIVE; E|P

Additive Metallisierung von im Spritzguss hergestellten Keramiken mittels Plasma-Coating-Technologie - Braun, Thomas; Greiner, Sandra; Baierl, Ullrich; Drummer, Dietmar; Franke, Jörg (PLUS - Produktion von Leiterplatten und Systemen, 2017)

ADDITIVE METALLIZATION OF INJECTION MOLDED CERAMIC COMPONENTS BY A PLASMA-COATING PROCESS - Braun, Thomas; Greiner, Sandra; Diepgen, Antonia; Schröppel, Kerry; Drummer, Dietmar; Franke, Jörg (Proceedings of the SMTA Pan Pacific Microelectronics Symposium, 2017, 2017)
Electronic components are increasingly used in high-temperature environments like automotive and aerospace applications. For these applications, miniaturization is gaining importance so that traditional methods and materials encounter their limits.  Therefore, with high thermal and chemical stability, ceramic materials offer an abundance of possible applications in the electronic circuit board sector. Furthermore, regarding miniaturization and increase of the functional density, electronic and mechanical components have to be merged. Reducing process time an alternative technology has to be found for applying a conductor track on a three-dimensional surface in little time. This paper shows the whole production chain of the manufacturing of a three-dimensional mechatronic integrated device based on ceramics, beginning with the injection molding of different ceramic-based materials in four process steps: compounding, injection molding, two-step debinding and sintering. For metallization of the ceramics, the paper presents an innovative plasma-coating technology. Thereby, a conductor track can be produced in only one process step within a few seconds without pre and post processing and without chemical substances. The system consists of two units: In one, the plasma generation module and the metal powder storage are hosted. In the other, the handling system and the plasma nozzle are located. In the plasma nozzle, the stream of carrier gas is ionized by an electric arc and is turned into a plasma state. The nozzle is fed with copper powder by two independent inert gas flows. Due to the high energetic plasma flame, the metal powder is melted and accelerated toward the surface of the substrate. A six-axis robot is used for handling the specimen and regulates the process speed, the distance between the nozzle and ceramic basic substrate as well as the applied layers to obtain the desired electrical and mechanical properties. The paper also shows the influence of the most important parameters for the metallization process, which can be summarized in four main groups: the used substrate, the metal powder, the plasma generation and the handling. After that, different passivation materials are tested to protect the generated copper conductor tracks from corrosion and mechanical influences. Furthermore, the paper will describe the effects of using conductive adhesive and soldering paste for contacting electrical components on the plasma-coated surface. The paper also presents investigations regarding the electrical resistance of the conductor tracks, the adhesive strength of the additively applied metal structures, and the maximum resistance to mechanical load before removing the electronic parts. The results of long-term tests deliver valuable information about the capabilities for a permanent use in automotive applications. Due to the basic research, the paper will present different demonstrators, which will show various areas of applications. To show the advantages of ceramic materials, three-dimensional circuit carriers are exposed to extreme conditions like heat and chemicals. Due to the high temperature resistance, this technique can be used to build a temperature sensor, which can be installed near to hot engines or inside a battery for directly measurement of the temperature.
Keywords: MID; Plasma-Coating; Plasmabeschichten; Additive Metallisierung

Additive Plasma Metallization of Spatial Ceramic Injection Molded Components - Braun, Thomas; Greiner, Sandra; Franke, Jörg; Drummer, Dietmar (12th International Congress Molded Interconnect Devices, 2016)

Additive Plasma Metallization of Spatial Ceramic Injection Molded Components - Braun, Thomas; Greiner, Sandra; Franke, Jörg; Drummer, Dietmar (12th International Congress Molded Interconnect Devices (MID): Scientific Proceedings, 2016)
UnivIS-Import:2017-12-18:Pub.2016.tech.FT.FT-KT.additi_6
Keywords: Additive metallization; Alumina; Ceramic injection Molding; Molded Interconnect Device; Plasma-coating; Surface Roughness

Additive waveguide manufacturing for optical bus couplers by aerosol jet printing using conditioned flexible substrates - Lorenz, Lukas; Nieweglowski, Krzysztof; Wolter, Klaus-Jürgen; Bock, Karlheinz; Hoffmann, Gerd-Albert; Overmeyer, Ludger; Reitberger, Thomas; Franke, Jörg (21st European Microelectronics and Packaging Conference and Exhibition, EMPC 2017, 2018)
In this work we present the additive manufacturing of optical multimode waveguides on flexible foil by aerosol jet printing. In order to obtain higher aspect ratios for the waveguides, the foils are conditioned by a flexographic printing step in advance. This technique is used to manufacture asymmetric bus couplers, which allow for coupling without waveguide interruption. They follow the working principle of directional core-core-couplers but have different coupling ratios depending on the coupling direction, due to a bending of one of the coupling partners. The latest results on the printing process are shown, especially the laser structuring of the flexographic printing form to optimize the condition lines. Also the attenuation of the printed waveguides is measured as well as the coupling results of the asymmetric bus coupler. Especially the coupling powers and the strength of the asymmetric effect are shown<br
Keywords: polymer multimode waveguides; optics on surfaces; photonic packaging; additive manufacturing; optical bus-coupling; directional coupler

Additiv gefertigte Handprothese - Yoo, In Seong; Reitelshöfer, Sebastian; Franke, Jörg (Technische Unterstützungssysteme, 2015)
Keywords: Additive Manufacturing; B|Mech; Prothetik

A Design for an Urban Electricity Market to Reduce the Expansion of the Low Voltage Distribution Grid - Teske, Franz; Wittl, Iris; Funk, Felix; Fehrle, Adrian; Franke, Jörg (2021 IEEE Electrical Power and Energy Conference (EPEC), 2021)
The transition from a centralized to a decentralized energy system is driven by prosumers, i.e., private households who operate flexible decentralized energy systems (DES). The demand and supply peaks resulting from their volatile consumption and generation can lead to grid bottlenecks and thus make expensive grid expansion necessary. Therefore, various approaches to use the existing power grid more efficiently by controlling private DES are being researched. In this paper, we propose a smart market platform (SMP) that reduces the need for grid expansion and incentivizes prosumer participation. The SMP also avoids grid congestions in the short term and provides suitable investment incentives in the long term. We conduct a scenario analysis to demonstrate that even using limited grid infrastructure, energy demands can be met in most scenarios. Our results show that market-based and decentralized coordination of control measures to reduce grid expansion can achieve advantages over existing solutions. These include more efficient asset dispatch in the short term, long-term investment incentives and, integration of different DES as well as individual needs of prosumer

A development approach towards user-centered front-ends for knowledge-based engineering configurators: a study within planning of robot-based automation solutions - Schäffer, Eike; Shafiee, Sara; Frühwald, Tobias; Franke, Jörg (Proceedings of the 22nd International Configuration Workshop, 2020)
Configurators are well-established strong researched expert systems due to the high popularity and gained benefits. Nevertheless, the aspects of user-centered design are rarely researched and applied during the development of configurator front-ends. However, when addressing a mass consumer market or non-experts end-users, the front-end represents the required crucial knowledge that bridges the end-user's current level of knowledge to the experts' knowledge. In order to push the application of knowledge-based engineering configurators for a mass market in SMEs, a user-centered configurator frond-end for the concept planning of robot-based automation systems is being developed within the platform project ROBOTOP. In this paper, the design of an architectural user-centered layer and a ten-step development approach of user-centered front-ends are presented.<br
Keywords: ROBOTOP; configurator; user-centered; UCD; user experience; front-end development; robot-based automation; planning; knowledge-based engineering

Adhesion Measurements for Printed Electronics: A Novel Approach to Cross Cut Testing - Schirmer, Julian; Roudenko, Jewgeni; Reichenberger, Marcus; Neermann, Simone; Franke, Jörg (41st International Spring Seminar on Electronics Technology (ISSE), 2018)
A silver paste was screen-printed on flexible polyethylene terephthalate (PET) substrates, pretreated with different methods. The adhesion quality was evaluated by a modified cross cut test method implementing a motorized cutting device. Additionally, a semi automatized image analysis method was proposed for the evaluation of cross cut patterns in order to quantify the peeled-off area after tape removal. The feasibility of this novel approach is verified by comparing the results with a standard pull off test. The results show that by implementing image analysis methods the area of paste removed by the adhesive tape can be accurately calculated in an automated way, making it possible to gain quantifiable, user independent and therefore more significant results. Furthermore, the results from cross cut test and from pull off test show a similar trend.<br

A digital twin to overcome long-time challenges in photovoltaics - Lüer, Larry; Peters, Ian Marius; Smith, Ana-Suncana; Dorschky, Eva; Eskofier, Björn; Liers-Bergmann, Frauke; Franke, Jörg; Sjarov, Martin; Brossog, Matthias; Guldi, Dirk Michael; Maier, Andreas; Brabec, Christoph (Joule, 2024)
The recent successes of emerging photovoltaics (PVs) are largely driven by innovations in material science. However, closing the gap to commercialization still requires significant progress to match contradicting requirements, such as performance, longevity, and recyclability. In this perspective, we envision the layout of a digital twin for PV materials able to provide the necessary acceleration of innovation. The layout combines machine learning approaches, as performed in materials acceleration platforms (MAPs), with physical models and digital twin concepts used in engineering. This layout will allow the use of high-throughput (HT) experimentation in MAPs to improve the parametrization of quantum chemical and solid-state models. In turn, the improved and generalized models can be used to obtain the crucial structural parameters. HT experimentation will thus yield a detailed understanding of generally valid structure-property relationships. We discuss the current state of the enabling technologies, namely fast scale-bridging surrogate models and large-scale optimization under uncertainty, and identify promising approaches for further development.<br
Keywords: digital twin; emerging photovoltaics; artificial intelligence; multi-scale simulations; optimization; high-throughput methods; materials acceleration platforms

Advanced substrate and packaging concepts for compact system integration with additive manufacturing technologies for high temperature applications - Syed Khaja, Aarief Hussain; Schwarz, Daniel; Franke, Jörg (IEEE CPMT Symposium Japan 2015, ICSJ 2015, 2015)
Additive manufacturing is one of the key technologies which poses as an energy and resource efficient alternative of conventional subtractive and formative technologies. In this contribution, additive layered manufacturing mainly selective laser melting (SLM) is investigated to check the potential for system integration and packaging concepts. This paper gives an overview on the limitations of conventional molded integrated devices for high temperature applications. For high temperature stability, ceramic substrates were additively functionalized with copper based powder material using SLM technique. Focus of the work lies in the melting of the metal powder directly on ceramic substrate and producing a reliable metal-ceramic bond. The process influencing parameters such as laser power, velocity, scan concepts were tested to check the bonding characteristics. Initial shear tests and current carrying tests were performed to check the mechanical and electrical stability. The proof-of-concept was demonstrated by developing a prototype in automotive lighting application. The potential of SLM for high-temperature applicability is further discussed.
Keywords: Additive Manufacturing; Electronics Packaging; High temperature; Mechatronic Integrated Devices; Selective Laser Melting; Substrate technologies

Advances in energy-related plant simulation by considering load and temperature profiles in discrete event simulation - Mayr, Andreas; Lechler, Tobias; Donhauser, Toni; Metzner, Maximilian; Schäffer, Eike; Fischer, Eva; Franke, Jörg (Procedia CIRP, 2019)
Discrete event simulations are one of the most used techniques by manufacturing system designers. In order to extend the traditional material flow with an advanced energy simulation, this paper presents two specially developed extension modules for the widely used software Tecnomatix Plant Simulation. In contrast to other approaches, the FAPS energy module is not only based on fixed values, but on measured load profiles. Furthermore, the FAPS temperature module for tracking the products’ temperature through the whole process chain is introduced. The latter module is particularly suited for identifying savings potential in energy-intensive thermal processe
Keywords: discrete event simulation; plant simulation; energy simulation; load profile; load management; temperature profile

Advances in Quality Monitoring of Stray Fields on Rotors of Permanent Magnet Synchronous Motors - von Lindenfels, Johannes; Urban, Nikolaus; Mayr, Andreas; Meyer, Alexander Wilhelm; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

A Dynamic Simulation Model of Industrial Robots for Energy Examination Purpose - Paryanto, Paryanto; Hetzner, Alexander; Brossog, Matthias; Franke, Jörg (Energy Effiency in Strategy of Sustainable Production, 2015)
Keywords: Energy consumption; industrial robot; control system; mechatronic simulation

Aerial Grasping and Transport Using an Unmanned Aircraft (UA) Equipped with an Industrial Suction Gripper - Lieret, Markus; Kreis, Benedikt; Hofmann, Christian; Zwingel, Maximilian; Franke, Jörg (Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021, 2022)
Due to the availability of highly efficient unmanned aircraft (UA) and the advancement of the necessary technologies, the use of UA for object manipulation and cargo transport is becoming a more and more relevant research area. A reliable identification and localization of cargo and interaction objects as well as maintaining the required flight precision are essential to guarantee a successful object handling. Within this paper we demonstrate the successful application of an autonomous UA equipped with a lightweight suction gripper for object interaction. We discuss the approach used for precise localization as well as the identification and pose estimation of individual gripping objects. Concluding, the overall system performance is evaluated within an industrial-oriented use case.<br
Keywords: Autonomous unmanned aircrafts; Flying robots; Aerial grasping; Object detection; Localization

Aerosol jet printed AgNW electrode and PEDOT:PSS layers for organic light-emitting diode devices fabrication - Hamjah, Mohd Khairulamzari; Steinberger, Marc; Tam, Kai Cheong; Egelhaaf, Hans Joachim; Brabec, Christoph; Franke, Jörg (2021 14th International Congress: Molded Interconnect Devices, MID 2021 - Proceedings, 2021)
Aerosol jet printing is a cutting-edge technology offering a plethora of advantages in organic optoelectronics fabrication. In this work, we fabricated organic light-emitting diodes on glass substrates. Silver nanowires (AgNWs) and poly (3,4-ethylene dioxythiophene) polystyrene sulfonate (PEDOT:PSS) were aerosol-jet printed as the bottom electrode and hole transport layer, respectively. The other remaining layer materials were blade coated to form a multi-layered structure of the devices. The results show that the organic lightemitting diode device with 40 mm2 active areas was successfully obtained. A comparison study of blade-coated organic light-emitting diode devices on indium tin oxide based electrode is also discussed. The results of this work show that aerosol jet printing technology enables fully solution-based fabrication of organic light-emitting diode devices.
CRIS-Team Scopus Importer:2021-04-02
Keywords: 4-ethylene dioxythiophene) polystyrene sulfonate; aerosol jet printing; organic light-emitting diode; poly(3; silver nanowires

Aerosol-Jet-Printed Encapsulation of Organic Photovoltaics - Basu, Robin; Siah, Kok Siong; Distler, Andreas; Häußler, Felix; Franke, Jörg; Brabec, Christoph; Egelhaaf, Hans-Joachim (Advanced Engineering Materials, 2023)
Organic electronic devices (OEDs) are prone to oxygen- and water-induced degradation and therefore need to be encapsulated with barrier materials. In this work, an aerosol jet (AJ)-printing process is developed to coat perhydropolysilazane (PHPS) directly onto OEDs by adapting the print setup and systematically optimizing the process parameters. Furthermore, a novel curing process that converts PHPS to silica barrier layers is developed by combining damp heat (DH) exposure with subsequent vacuum–UV irradiation. This two-step treatment is shown to be considerably faster and gentler than the state-of-the-art curing processes and also yields a quantitatively higher conversion. Both the printing and the conversion process are fully compatible with OED devices, which is demonstrated by a damage-free direct encapsulation of organic solar cells. The encapsulated cells show a significant reduction of degradation in DH conditions (65 °C/85% r.h.), maintaining >95% of their initial performance for >100 h. Complementary electroluminescence measurements reveal that the AJ-printed barrier layers effectively prevent lateral water ingress into the devices. Herein, the proof of principle is provided that AJ printing can be used to print barrier layers directly onto OEDs and is thus an industrially highly relevant technology to precisely encapsulate such devices even on 3D objects.
CRIS-Team Scopus Importer:2023-07-07
Keywords: aerosol jet printing; organic solar cells; perhydropolysilazane; printed barriers; solution-processed encapsulation

Aerosol Jet Printed Optical Waveguides for Short Range Communication - Lorenz, Lukas; Nieweglowski, Krzysztof; Al-Husseini, Zaid; Neumann, Niels; Plettemeier, Dirk; Reitberger, Thomas; Franke, Jörg; Bock, Karlheinz (Journal of Lightwave Technology, 2020)
This article presents an innovative way for additive manufacturing of optical multimode waveguides for short range data transmission. By the use of aerosol jet printing between conditioning lines on flexible foils, low cost, and low weight polymer optical waveguides can be easily fabricated. The main advantages - compared to other waveguide manufacturing techniques - are the maximum fabricable waveguide length (not limited by panel- or wafer size), technology costs and 3D-ability. Furthermore, the printing allows for very long structures, which are not limited to wafer or panel sizes. In order to classify the new manufacturing approach and compare it to other technologies such as photolithography, imprinting, dispensing and ion-exchange, results on the mechanical (shear strength) and optical performance (transmittance, near field and attenuation) are presented. In addition, the experimental results on the data transmission performance are important to prove the suitability of the waveguides for high-speed communication applications. In this context, nearly error-free transmission up to 10 Gbit/s was achieved at a wavelength of 850 nm.
CRIS-Team WoS Importer:2020-07-31

Aerosol jet printing and lightweight power electronics for dielectric elastomer actuators - Landgraf, Maximilian; Hedges, Martin; Reitelshöfer, Sebastian; Franke, Jörg (3rd International Electric Drives Production Conference (EDPC), 2013)
Dielectric elastomer actuators have been subject of researches in materials science since almost two decades. The synonymous denotation “artificial muscles” emphasizes the potential capability of those actuators, whereat the skeletal muscles of mammals, which are the biological archetypes, even are exceeded pertaining energy density and efficiency. These new kind of actuators depicts promising actuators for the development of a new generation of robotic solutions, such as inherently safe systems for human robot cooperation, highly dynamical, mobile and energy autarkic kinematics or even prosthetics. Since there are several challenges to be handled, like the high supply voltage, no automated manufacturing process for multilayered dielectric elastomer actuators is available and thus no actuators systems based on dielectric elastomer actuators for complex robot kinematics or commercial products. Now the Aerosol Jet Printing process seems suitable for an automated manufacturing process by printing such actuators and is investigated within the framework of the Bavarian biomimetic initiative “bionicum-forschung”. With this additive process stacked actuators are printed, where insulating and conducting layers are alternating and the automated manufacturing of stacked actuators with thousands of layers seems possible in the long term. With the new built actuators, new mobile and autarkic platforms in the range of a capuchin will be designed. Therefore lightweight power electronics are necessary, which investigation represents the second main research task within the project. Here only one high-mass central power supply is able to individually operate each of the artificial muscles on the platform with a pulse width modulated high voltage signal. Thus each actuator does not need its own supply. The presented project aims with the development of a mobile and autarkic platform the improvement of actual robot platforms regarding to dynamical int- ractions with the environment, like jumping, and the progress of the actual state of the art of robotics.
Keywords: aerosols; biomimetics; electroactive polymer actuators; mobile robots; power electronics; robot kinematics; Bavarian biomimetic initiative; additive process stacked actuators; aerosol jet printing process; artificial muscles; autarkic platforms; automated manufacturing process; biological archetypes; bionicum-forschung; capuchin; complex robot kinematics; conducting layers; energy density; high-mass central power supply; human robot cooperation; insulating layers; lightweight power electronics; mammals; mobile platforms; multilayered dielectric elastomer actuators; pulse width modulated high voltage signal; robot platforms; robotic solutions; skeletal muscles; Actuators; Aerosols; Electrodes; Materials; Printing; Pulse width modulation; Switches; aerosol jet printing; artificial muscles; dielectric elastomer actuators; electroactive polymers; high voltage pulse width modulation; lightweight actuators; stacked actuators

Aerosol Jet Printing and Lightweight Power Electronics for Dielectric Elastomer Actuators - Landgraf, Maximilian; Hedges, Martin; Reitelshöfer, Sebastian; Franke, Jörg (Proceedings of the 3rd International Electric Drives Production Conference (EDPC), 2013)

Aerosol Jet® printing of optical waveguides - Reitberger, Thomas; Hörber, Johannes; Schramm, René; Sennefelder, Simon; Franke, Jörg (38th International Spring Seminar on Electronics Technology, ISSE 2015, 2015)

Aerosol-Jet-Printing silicone layers and electrodes for stacked dielectric elastomer actuators in one processing device - Reitelshöfer, Sebastian; Göttler, Michael; Schmidt, Philip; Treffer, Philipp; Landgraf, Maximilian; Franke, Jörg (SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, 2016)
In this contribution we present recent findings of our efforts to qualify the so called Aerosol-Jet-Printing process as an additive manufacturing approach for stacked dielectric elastomer actuators (DEA). With the presented system we are able to print the two essential structural elements dielectric layer and electrode in one machine. The system is capable of generating RTV-2 silicone layers made of Wacker Elastosil P 7670. Therefore, two aerosol streams of both precursor components A and B are generated in parallel and mixed in one printing nozzle that is attached to a 4-axis kinematic. At maximum speed the printing of one circular Elastosil layer with a calculated thickness of 10 μm and a diameter of 1 cm takes 12 seconds while the process keeps stable for 4.5 hours allowing a quite high overall material output and the generation of numerous silicone layers. By adding a second printing nozzle and the infrastructure to generate a third aerosol, the system is also capable of printing inks with conductive particles in parallel to the silicone. We have printed a reduced graphene oxide (rGO) ink prepared in our lab to generate electrodes on VHB 4905, Elastosil foils and finally on Aerosol-Jet-Printed Elastosil layers. With rGO ink printed on Elastosil foil, layers with a 4-point measured sheet resistance as low as 4 kΩ can be realized leaving room for improving the electrode printing time, which at the moment is not as good as the quite good time-frame for printing the silicone layers. Up to now we have used the system to print a fully functional two-layer stacked DEA to demonstrate the principle of continuously 3D printing actuators.

Aggregated power quality indicator for controlling a hybrid compensation system providing system services - Merkl, Ralf; Steglich, Michael; Paulsburg, Martin; Rehtanz, Christian; Franke, Jörg (IEEE PES Innovative Smart Grid Technologies Conference Europe, 2020)
In electric energy distribution, a defined level of power quality is to be maintained at all times to ensure reliable grid operation. Increased connection of power electronic feeders and loads as well as fluctuating power plants introduces time-varying power quality deviations. Within this article, we propose a concept for determining the present level of power quality and distributing the available power of a compensation system to individual services. Focusing on steady-state phenomena of power quality as harmonics, unbalance, frequency, voltage level and phase angle we calculate an aggregated indicator of the present power quality level. By applying well known procedures for calculation of individual power quality parameters we obtain required data for determining the aggregated power quality index. Restrictions are imposed by means of dead bands and limits specified by power quality standards.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Aggregated power quallity index; Grid support; Power quality; System services

A hybrid compensation system for provision of ancillary services in medium voltage grids - Böhm, Ralf; Steglich, Michael; Baucrnschmitt, Bjorn; Rehtanz, Christian; Franke, Jörg (2018 International Conference on Diagnostics in Electrical Engineering, Diagnostika 2018, 2018)
Medium voltage grids are subject to a change in load situation due to the installation of decentralized generation plants. Predominantly load symmetry, active and reactive power flows as well as requirements for the necessary capacity of earth fault compensation are affected. Decentralized generation connected through power electronics as well as consumers using switching power supplies cause distortions. Furthermore, electrical energy storage is gaining importance within rural distribution networks to compensate fluctuating generation plants. A hybrid compensation system can contribute to provision of adequate power quality by integrating several ancillary services into a single device. In this article the design of the hybrid compensation system is introduced and it is evaluated, which ancillary services in medium voltage distribution grids are likely to be provided using an inverter-based hybrid compensation system and a hybrid storage system.
CRIS-Team Scopus Importer:2023-03-07
Keywords: ancillary services; hybrid compensation system; hybrid storage system; power quality

A Hybrid Metric for Navigation of Autonomous Intralogistics Vehicles in Mixed Indoor and Outdoor Operation - Zwingel, Maximilian; Schuderer, Peter; Franke, Jörg (Proceedings of the Conference on Production Systems and Logistics: CPSL 2022, 2022)
While autonomous guided vehicle systems are increasingly used in homogeneous and structured environments, their use in complex and variable scenarios is usually limited. Established algorithms for the navigation of systems use static maps with deterministic metrics, which can only achieve optimal results in clearly defined environments. In dynamic and extensive deployment scenarios, which are also dependent on a large number of influencing parameters, autonomous intralogistics systems cannot yet be deployed dynamically. One example here is mixed transport between buildings under changing weather conditions. As a solution for dynamic navigation, we propose a hybrid metric in combination with topological maps and cyclic environmental sensing. Based on a quantification of influencing factors on each intralogistics entity, an optimal and dynamic navigation of every system can be performed at any time. The individual components are implemented in the context of an autonomous tow truck system and evaluated in different application scenarios. The results show significant added value in use cases with sudden weather changes and complex route network
Keywords: Autonomous Production Systems; Industry 4.0; Production networks; Logistics; Digitalization

A Hybrid Transport Concept for the Material Supply of a Modular Manufacturing Environment - Scholz, Michael; Serno, Mario; Franke, Jörg; Schuderer, Peter (FAIM 2017, 2017)

AI-based approach for predicting the machinability under consideration of material batch deviations in turning processes - Lutz, Benjamin; Kißkalt, Dominik; Regulin, Daniel; Franke, Jörg (Procedia CIRP, 2020)
A significant difference in the machinability of hard-to-machine materials can be observed among different batches of the same specified material. Thus, for cost-efficient machining, the ideal point of operation may vary for each batch. To investigate this, more than 1000 experiments at different cutting conditions with ten material batches are carried out. This data is used to train a support vector machine, capable of predicting a machinability index based on the material batch and the cutting conditions. The derived model is implemented as a cloud-based service, enabling its integration into a smart manufacturing assistant. It can be used for process optimization by predicting the machinability for given situations and, thus, finding the point of operation with favorable machinability.<br
Keywords: Artificial intelligence; Machine learning; Smart manufacturing; Process optimization; Machining

A lightweight, low-cost and self-diagnosing mechatronic jaw gripper for the aerial picking with unmanned aerial vehicles - Lieret, Markus; Lukas, Jakob; Nikol, Markus; Franke, Jörg (Procedia Manufacturing, 2020)
Within recent years the gripping and manipulation of individual objects using unmanned aerial vehicles (UAVs) has become an area of broad scientific research as UAVs allow a fast and three-dimensional transportation of the grasped objects. However, currently there are neither standards for aerial gripping devices nor are there grippers available that are both lightweight and robust enough for the usage with drones and can provide the required feedback on whether the gripping process was successful. In this paper, we therefore present a lightweight, low-cost and self-diagnosing mechatronic jaw gripper for the application with autonomous UAVs. The gripper offers an energy-saving design and an integrated measurement system to detect whether an object was successfully grasped. To evaluate the performance of the gripper it is attached to a quadrotor and tested within different scenarios. The tests include the detection of successfully grasped or dropped out objects and the autonomous pickup and deposit.
Keywords: aerial grasping; gripper technologies; autonomous aerial vehicles; object interaction; robotics

A machine learning approach to estimate product costs in the early product design phase: a use case from the automotive industry - Bodendorf, Frank; Franke, Jörg (Procedia CIRP, 2021)
The management and controlling of product costs play an important role in the early stages of value creation, since 70 - 80 % final product costs are determined in product development and design processes. Traditionally, the focus in business practice is often on the organizational controlling unit that records the corresponding costs when they occur. In those, later phases of the product lifecycle, the possibilities of exerting influence are very limited. Consequently, an accurate estimation of costs in the early design phase is an important instrument to support strategic decisions in the product engineering process. An intelligent approach based on machine learning to support cost management in the early design stage is presented. In a real-world case study using wheel cost data from a large original equipment manufacturer (OEM) we investigate the performance of a cross-validated machine learning framework using a greedy sequential forward feature selection method for dimensionality reduction, as well as grid search hyperparameter tuning in order to compare six regression algorithms. The results of the study show that it is possible to predict the costs of product components in the early design phase with an R2 of 0.960 using only seven features coming from the product design and development department. By a cluster analysis and scatter plots of prediction accuracies it is shown where the deviations in cost estimation come from. The study supports the statement that machine learning models are a promising instrument for product managers and cost engineers.<br
Keywords: Cost Estimation; Machine Learning; Design Stage; Automotive Industry

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False calls are an undesired occurrence in manufacturing of printed circuit boards that have to be verified manually after the automated optical inspection

A method for collaborative knowledge acquisition and modeling enabling the development of a knowledge-based configurator of robot-based automation solutions - Schäffer, Eike; Fröhlig, Simon; Mayr, Andreas; Franke, Jörg (Procedia CIRP, 2019)
When it comes to the development of knowledge-based configurators, there is a lack of procedures for the collaborative work on knowledge acquisition and modeling. However, the division of work is inevitable, especially in interdisciplinary application domains such as the configuration of automation solutions. Therefore, this paper presents a practicable method, enabling the collaborative development of a knowledge-based configurator across various partners and locations. The developed method is divided into eight steps: Firstly, economically relevant use cases are identified so that the necessary human and financial resources are released by the management. Secondly, several best practices, in this case successfully implemented robotic-based automation solutions, are collected. In the third step, generic, cross-case topological elements are extracted. Building on the relevant topological elements, constraints for the formation of the configuration logic are derived in the fourth step. In the fifth step, the required attributes are deduced from constraints and implemented within the data schema. The integration of the constraints, as well as the data schema in the configuration framework, takes place in the sixth step. In the seventh step, concrete components, e.g. individual end effectors, robot arms or controllers, are collected and prepared according to the data schema and integrated into the configurator. In the eighth and last step, the configurator is tested by comparing given configurations with known best practices. By deriving new constraints from the identified discrepancies and by analyzing new best practices, the resulting configurator can then be optimized iteratively. In addition, an auxiliary tool to support single steps of the method is introduced. For validation purposes, a suitable configuration model for robot-based automation cells was designed, distinguishing between scenario, product, processes and resources.<br
Keywords: knowledge acquisition; knowledge modeling; configuration; engineering; constraints; collaboration; method; 150% topology; S-PPR model

A Method for Forecasting the Running Costs of Manufacturing Technologies in Automotive Production during the Early Planning Phase - Bornschlegl, Martin; Kreitlein, Sven; Bregulla, Markus; Franke, Jörg (Procedia CIRP, 2015)
The running costs of production sites are a decisive factor in the overheads of automotive production. Because of this, it is important for many operators to decrease those costs in a sustainable way. Therefore, they try to reduce both the energy consumption costs of production systems, as well as their maintenance costs. However, most parts of the running costs are already determined during the very early phases of the product creation process. The approach in this paper shows how the decision for a specific manufacturing technology influences the factory costs. It is necessary to determine the life-cycle costs with regard to the manufacturing technology. Therefore, deep knowledge about the process itself and the support processes is required. This paper shows how cost relevant parameters can be identified and introduces a method to determine the prospective costs for maintenance and energy consumption in advance.
Keywords: Factory planning; Holistic planning process; Life-cycle costing; Sustainable manufacturing; Running costs

A Methodology for Predictive Life Expectancy of Moisture-Sensitive SMT components using Neural Networks - Schmidt, Konstantin; Haas, Lukas; Latifi Bidarouni, Amir; Reinhardt, Andreas; Döpper, Frank; Franke, Jörg (Procedia CIRP, 2022)
With the increasing demand for climate-neutral production procedures, resource efficiency plays a significant role. In addition, chip shortage happened due to COVID-19, for example, costs for the global automotive industry were 210 billion in revenue in 2021 only, showing the importance of electronic components in the industry and the necessity of taking action to tackle the chip-waste problem in the production line. The circumstances show that chip availability and efficient use are gaining relevance. This also includes the optimal utilization of environmentally sensitive components to avoid waste. As for components sensitive to humidity, moisture is absorbed when they are not handled under dry conditions. In the production, after the opening of sealed packages, this causes problems such as a fracture in micro scales to inflation or popcorning of the component. Established norms like JEDEC often suggest baking the components for de-moisturizing or disposal of the components. The exact environmental condition is hardly taken into account. This yields to extra energy consumption for unnecessary drying on the one hand or waste of components on the other hand. In this contribution, the authors suggest a methodology to predict the weight change of SMT components due to moisture absorption/desorption based on environmental conditions using a Machine Learning model. In this regard, one can decide for each component individually, if it needs to be dried based on the real amount of moisture absorbed and consequently, prevent the component failure in the production procedure. Temperature, humidity, and weight change of components are measured with the Magnetic Suspension Scale (MSC) and Thermogravimetric Analyzer (TGA) over time and under defined environmental conditions. To predict the weight change over a defined period, a Recurrent Neural Network has been trained which has shown a reasonable accuracy in predicting the weight change. Furthermore, to generalize the trained model for different types of components, parameters like dimensions and density are fed into the model to represent their physical characteristics. For the validation three different component types, classified for the Moisture-Sensitivity-Level 4 (MSL) are use
Keywords: Electronics Production; Machine Learning; Humidity; Deep Learning; Predictive Quality; Moisture Sensitivity Level

A Microservice- and AutomationML-based Reference Architecture for an Engineering Configurator Web Platform - Schäffer, Eike; Penczek, Lars; Bartelt, Matthias; Brossog, Matthias; Kuhlenkötter, Bernd; Franke, Jörg (9th CIRP Global Web Conference – Sustainable, resilient, and agile manufacturing and service operations : Lessons from COVID-19, 2021)
Robot-centric automation solutions (RAS) promise more efficiency and quality in production as well as more economic stability and security through local production, especially in the times of COVID-19. Nevertheless, due to their high complexity and costs, RAS are only used to a limited extent by small and medium-sized manufacturing companies. As a rule, the high costs of RAS arise from individual engineering, which takes up to 70 percent of the acquisition costs. For this reason, it is necessary to optimise the engineering of RAS. Among other things, better software and less costly top-down engineering methods are needed for this kind of enhancement. Pure optimisation via more advanced simulation tools is not sufficient. Configurators in particular offer the possibility of automatically arranging individual solutions from existing experience. Up to now, however, configurators have been used primarily for the individualisation of products, such as automobiles or clothing, on the basis of the variants predefined by the manufacturer, and less for the engineering of automation solutions. To make top-down configuration and simulation functions easily available to small medium enterprises, a web platform is a convenient solution. Due to the high complexity within the engineering domain, it is reasonable to build this kind of web platform with different services from specialised companies, e.g. by using microservices (MS). Conceivable roles could be as following. The web platform operator (WPO) offers an industry-specific, turnkey complete web platform. The WPO combines, integrates and orchestrates various modules and MS like configuration, simulation, data exchange and other. The MS can be provided by MS providers. In particular, since data interoperability and exchange are very important for engineering, an AutomationML (AML) MS is used to implement both. AML particularly supports the generic exchange of data based on industrial standards. To provide a general solution, a MS and AML-based web platform reference architecture was developed. These concepts and MS architecture are validated via a prototypical implementation and utilisation of the web platform within the scope of the ROBOTOP research project. Thus, the potential for increasing efficiency in engineering for RAS could be demonstrated using this top-down approach.
Keywords: AML; Automation; AutomationML; configurator; Engineering; KBEC; knowledge-based; planning; robot; web platform

A Microservice-Based Architecture for Flexible Data Acquisition at the Edge in the Context of Hairpin Stator Production - Raffin, Tim; Mayr, Andreas; Fuchs, Jonathan; Baader, Marcel; Morello, Andreas; Kühl, Alexander; Franke, Jörg (2021 11th International Electric Drives Production Conference (EDPC), 2021)
Data-driven technologies such as machine learning promise great potentials for electric drives production. However, present information systems do not allow flexible and reliable accumulation of high-dimensional data such as images and time series, so feature-rich data are often discarded in practice. The advent of edge computing and microservice-based software architectures in recent years enables low latencies, high data integrity, and flexibility towards different communication protocols, thus offering new possibilities to accumulate data in a manufacturing environment. Hence, this paper proposes a microservice architecture deployed on the edge that serves as a communication layer between data sources and downstream data analytics capabilities. The architecture's flexibility is demonstrated and validated on different process steps along the process chain of hairpin stator production. In conclusion, the developed microservice architecture is suitable for reliable data acquisition at the edge and can enable subsequent machine learning analyses across the process chain.
Keywords: Software architecture; Soft sensors; Data acquisition; Time series analysis; Microservice architectures; Production; Computer architecture; Edge computing; data analytics; Machine learning; Hairpin technology; electric drives production

A mixed methods approach to analyze and predict supply disruptions by combining causal inference and deep learning - Bodendorf, Frank; Sauter, Maximilian; Franke, Jörg (International Journal of Production Economics, 2023)
In today's complex supply networks, disruptions caused by diverse events represent major unknown operational conditions and risk factors requiring research on supply chain risk management. Hereby, operations management (OM) researchers are traditionally focusing on defining analytical and mathematical risk mitigation strategies characterized by a variety of different constraints, such as capacities, timeliness, or relations, leading to limited transferability into practice. Given the complexity of modern supply chains we argue that a data-driven approach to supply chain risk management enhances the assessment and comparability of risk mitigation strategies. Thereby an approach that allows conclusions about causal relationships between supply chain interventions and potential outcomes is of particular importance. Inspired by deep learning as well as causal learning theory and following a design science research approach, we design an analytical model that can predict supply disruptions based on external and internal data and quantify causal effects on delivery reliability. The model is evaluated in a single case study using data from a large first tier automotive supplier. The results show that the model has a high predictive performance and can learn causalities from observed data and analyze interventions effecting supply disruptions. The identification of causal relationships offers the potential to identify lacking supplier relationships and consequently bundle supply chain risk management activities. Building on the empirical and analytical insights, we discuss implications for both theory and practice.
CRIS-Team Scopus Importer:2023-01-06
Keywords: Causal inference; Deep learning; Design science; Risk management; Supply chain management; Supply disruption

A Model-Based Approach for the Energy Monitoring of Handling Machines - Paryanto, Paryanto; Brossog, Matthias; Roppelt, Manuel; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production Vol. II, 2017)
Keywords: Handling systems; Energy consumption; Model-based approach; Cartesian robots; Mechatronic simulation

A model for integrating energy management in lean production - Javied, Tallal; Deutsch, Marius; Franke, Jörg (Procedia CIRP, 2019)
The implementation of sustainable production systems has been the focus of political, economic and social efforts for years. Due to the switch from fossil fuels to green energies, energy costs have been rising steadily for years. Energy-related taxes and levies can be reduced with a certified energy or environmental management system. ISO 50001 specifies requirements for the implementation of energy management system. Nevertheless, since 2017, ISO 50003 requires companies to demonstrate, by means of indicators, that energy efficiency is actually being continuously improved. Until now, only the proof, which shows that a systematic approach to reduce energy consumption is employed, was sufficient as a basis. However, the focus has now shifted towards the optimization of energy management systems. Nonetheless, these norms allow a wide scope for interpretation. This paper contains a methodology for the implementation of energy management system according to which companies can design there structure and processes to fulfil all the requirements specified in ISO 50001 and the other relevant energy management standards. The technical, business and organizational possibilities as well as the involvement of personnel along the McKinsey 7S model are considered. McKinsey's 7S change management tool provides the framework. The sustainable success of companies is analyzed using hard and soft factors. In this case, the model is applied to management systems.
CRIS-Team Scopus Importer:2019-12-31
Keywords: Energy management; ISO 50001; Process design

A model to assess the sustainability of manufacturing equipment using the example of a reusable frequency converter housing - Drechsel, Michael; Bomschlegl, Martin; Dornhofer, Andre; Spreng, Simon; Mackert, Roman; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
This model shows how manufacturing equipment can be assessed according to its global warming potential. A model to evaluate, compare and therefore to enable a more sustainable production is shown. With the use of this model automotive production planners can improve the transparency for sustainable solutions. In addition, the example of a reusable frequency converter housing for conveyor technologies is presented. The main focus within the assessment is on raw material, product cycles and their ecologic and economic effects on the assessment results. It is shown that the end of life phase has a great influence on the overall carbon footprint of manufacturing equipment. Furthermore, ecologic and economic saving potentials suggest to establish new business models integrating the exploitation of used equipment.
CRIS-Team Scopus Importer:2023-03-07
Keywords: global warming; green products; production planning; recycling; sustainable development

A Modular Architecture for the Design of Condition Monitoring Processes - Fleischmann, Hans; Kohl, Johannes; Franke, Jörg (Procedia CIRP, 2016)
The increasing complexity of production plants in the context of Industry 4.0 poses new challenges with regards to technical maintenance and process control. In this context, Cyber-Physical Systems (CPS) for intelligent condition monitoring enable fault-tolerant, predictable production systems. Unfortunately, CPS and Condition Monitoring System development is challenging due to the distribution of computational tasks among heterogeneous industrial IT-architectures. It is usually started from scratch, which is time-consuming and error-prone. In times of CPS the employee as maintenance worker, who ensures the availability of production machinery, is still important. In order to address these challenges, this publication we propose a modular architecture for Socio-CPS-based condition and process monitoring as well as fault diagnostics.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Condition Monitoring Systems; Industry 4.0; Socio-Cyber-Physical Systems; Technical Diagnosis

A Modular Interface for Controlling Interactive Behaviors of a Humanoid Robot for Socio-Emotional Skills Training - Seßner, Julian; Porstmann, Andy; Kirst, Simone; Merz, Nina; Dziobek, I.; Franke, Jörg (RO-MAN 2022 - 31st IEEE International Conference on Robot and Human Interactive Communication: Social, Asocial, and Antisocial Robots, 2022)
The usage of social robots in psychotherapy has gained interest in various applications. In the context of therapy for children with socio-emotional impairments, for example autism spectrum conditions, the first approaches have already been successfully evaluated in research. In this context, the robot can be seen as a tool for therapists to foster interaction with the children. To ensure a successful integration of social robots into therapy sessions, an intuitive and comprehensive interface for the therapist is needed to guarantee save and appropriate human-robot interaction. This publication addresses the development of a graphical user interface for robot-assisted therapy to train socio-emotional skills in children on the autism spectrum. The software follows a generic and modular approach. Furthermore, a robotic middleware is used to control the robot and the user interface is based on a local web application. During therapy sessions, the therapist interface is used to control the robot's reactions and provides additional information from emotion and arousal recognition software. The approach is implemented with the humanoid robot Pepper (Softbank Robotics). A pilot study is carried out with four experts from a child and youth psychiatry to evaluate the feasibility and user experience of the therapist interface. In sum, the user experience and usefulness can be rated positively.
CRIS-Team Scopus Importer:2022-11-04

A modular web framework for socio-CPS-based condition monitoring - Fleischmann, Hans; Kohl, Johannes; Franke, Jörg (IEEE International Workshop on Factory Communication Systems - Proceedings, WFCS, 2016)
The increasing complexity of production plants in the context of Industry 4.0 poses new challenges with regards to technical maintenance. In industrial domains, Condition Monitoring Systems (CMS) enable fault-tolerant, predictable production systems. Unfortunately, CMS development is challenging due to the distribution of computational tasks among heterogeneous industrial Internet of Things and Services (IoTS)-architectures. It is usually started from scratch, which is time-consuming and error-prone. In times of IoTS the employee as a maintenance worker, who ensures the availability of production machinery, is still important. In order to address these challenges, we propose a modular framework for web-based condition monitoring and fault diagnostics. The implementation relies on technologies such as Hypertext Markup Language 5 (HTML5), JavaScript (JS) and node.j s as well as industrial internet communication standards. Finally, verification and validation are performed in a case study on a modular robot cell for the inspection of electronic assemblies.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Communication Standards; Condition Monitoring Systems; Distributed Application Platforms; Maintenance; Socio-Cyber-Physical Systems

A Multimodal A∗ Algorithm to Solve the Two-Dimensional Optimization Problem of Accompanying a Person for an Intelligent Wheelchair - Kalenberg, Matthias; Lieret, Markus; Hofmann, Christian; Franke, Jörg (45th Annual International Conference of the IEEE Engineering in Medicine and Biology Conference, EMBC 2023, 2023)

A multi-perspective approach to support collaborative cost management in supplier-buyer dyads - Bodendorf, Frank; Xie, Qiao; Merkl, Philipp; Franke, Jörg (International Journal of Production Economics, 2022)
Joint cost management is a decisive factor for sustainable collaboration in supplier-buyer dyads. For both parties the establishment of an accurate cost estimation (CE) framework supports managing suppliers' costs as well as manufacturer's quotation costing. Grounded on resource dependence theory and following a design science research approach, this study introduces a multi-perspective CE system inspired by statistical learning, deep learning, decision making, and multi-agent theory. We evaluate our system by a single case and computer simulation study, using empirical data coming from observations and archives at a large Bavarian original equipment manufacturer (OEM). The results indicate that our CE approach allows to select the most significant cost-drivers and predict total costs of parts and assemblies with high accuracy. This supports the supplier in efficiently managing its costs. In making the CE blackbox model transparent using a combination of model agnostic post-hoc explainable artificial intelligence approaches we foster user acceptance for both suppliers and OEMs. All CE artifacts are ensembled in a multi-agent system to automatically manage costs with suppliers and furthermore, as a model extension, can lead to a collaborative price agreement. Our system supports supply chain managers on both sides in entering into a sustainable long partnership.<br
Keywords: Collaborative cost management; Purchasing; Machine learning; Decision support system; Manufacturing

A multi-physics simulation approach for energy and cost analysis during the deceleration of high-speed trains - Meinel, David; Javied, Tallal; Rast, Sebastian; Zipp, Christian; Franke, Jörg (Procedia Manufacturing, 2018)
The kinetic energy of cruising high-speed trains is significant and should be saved if possible. On the one hand, regenerative braking only goes along with a low deceleration rate due to the limited motor power and needs to be compensated with energy-wasting high travelling speeds in order to travel within a given schedule. On the other hand, travelling with lower speeds demands for adding wear-prone mechanical braking power to keep the speed up long enough. This dilemma makes for the scientific quest of this paper to examine these two opposing approaches using a multi-physics train model for simulations featuring distributed brake and motor models across the train model. The simulation scenarios herein are characterized by different ratios of disc braking forces and regenerative braking forces. Plainly electric braking turned out the most economical but less effective than adding mechanic braking force. A compromise strategy for both making for schedule buffers and achieve a satisfying efficiency has been found. Engaging the mechanic disc brakes turned out to be indispensable for avoiding schedule delays. A study about reinforcing the motor equipment to increase the braking capacity resulted in a potential improvement of the economic efficiency during the life cycle of trainsets.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy; high-speed; management; mechatronic; model; Modelica; multi-physics; simulation; train; train

A Multi-source Localization System for Driverless Material Transport in Mixed Indoor and Outdoor Areas - Herbert, Meike; Zwingel, Maximilian; Czapka, Christian; Franke, Jörg (Production at the Leading Edge of Technology, 2021)
To ensure material supply in production, the focus of research and development is on flexible, automated intralogistics solutions. The automation of material transport in mixed indoor and outdoor environments enabling transport processes between factory buildings is still challenging. The seamless localization of transport vehicles with the required accuracy is a core issue for navigation. While global navigation satellite systems can be used outdoors, other approaches like wireless networks or light detection and ranging technology are applied indoors. Additional sensors e.g. incremental encoders or inertial measurement units are used to create a multi-source localization system, which can adapt to the ideal mix of sensor sources, especially in transition areas. In this paper, a localization approach for driverless transport vehicles is presented in detail including applied methods for data fusion and implementation. The localization approach is validated using a tow truck equipped with sensors for autonomous transport.
Keywords: Intralogistics; Autonomous material transport; Localization

A multi-view deep learning approach for quality assessment in laser welding of hairpin windings based on 2D image captures - Mayr, Andreas; Bauer, Johannes; Franke, Jörg (Procedia CIRP, 2022)
Electric traction motors must meet high requirements in terms of efficiency in driving operation as well as cost-effectiveness in manufacturing. The so-called hairpin technology yields potential for both aspects. However, a central bottleneck in hairpin stator manufacturing is the contacting process, commonly performed by laser welding, where a large number of joints must be created. Since a single defective weld can lead to a failure of the whole stator, effective methods for quality assessment are needed. Building on preliminary work, this paper proposes a novel multi-view deep learning architecture for combined processing of pre- and post-process images to detect welded joints with an insufficient cross-section.<br

An adaptive, color based lane detection of a wearable jogging navigation system for visually impaired on less structured paths - Ramer, Christina; Seßner, Julian; Lichtenegger, Thomas; Landgraf, Maximilian; Franke, Jörg (2016 6th IEEE International Conference on Biomedical Robotics and Biomechatronics (BioRob), 2016)
Based on a previously published version of a first prototypic jogging navigation system for visually impaired and blind people, this paper presents an adaptive lane detection method that extents the use on standard running tracks to general and less structured paths. Additional and supporting developments refer to an active camera stabilization, the improved intuitive vibration feedback and the integrated and embedded mechatronic system setup.

Analysis of additive manufactured polymer optical waveguides: measurement and simulation of their waviness - Backhaus, Carsten; Hoffmann, Gerd-Albert; Reitberger, Thomas; Eiche, Yannic; Overmeyer, Ludger; Franke, Jörg; Lindlein, Norbert (Integrated Optics: Devices, Materials, and Technologies XXIV, 2020)
This paper analyzes an approach for additively manufacturing polymer optical waveguides. The production process includes flexographic printing of conditioning lines (5 μm height) on a substrate, which are used as guiding barriers in the subsequent printing of the optical core. The core is additively printed (up to 50 μm in height) with an aerosol jet printer, filling the gap between the conditioning lines. The conditioning lines do not only enhance the contact angle of the polymer, which results in a higher cross section of the waveguides, but also improve the straight edges of the printed waveguides. We show that the quality of the conditioning lines is directly correlated to the waviness of the waveguides. Consequently, the analyses of the waviness of the conditioning lines classifies the quality of the fabricated waveguides. However, the waviness of the waveguides can also be considered in optical simulations. In this paper we show how we derive a waveguide model with waviness by fitting a single sine function onto the topological data of the conditioning lines. With this model a variation of the waviness can easily be simulated and goals for fabrication can be set. With the simulations it is possible to verify that the measured waviness (period of 559.5 μm and an amplitude of 4.99 μm) does not affect the optical quality of the waveguide
Keywords: Polymer Optical Waveguides; Waviness; Additive Manufacturing; Waveguide Simulation; Aerosol Jet Printing

Analysis of induction-based thermal demagnetization of a permanent magnet rotor in the context of recycling - Ihne, Thorsten; Wieprecht, Nico; Hahn, Roman; Franke, Jörg; Kühl, Alexander (2023 13th International Electric Drives Production Conference, 2023)
Rare Earth (RE) Magnets are a key for many green technologies causing continuously increasing demand in the European Union (EU). Alongside motors for e-mobility and generators in wind turbines, compressors in domestic heat pumps represent a potential lever for slowing climate change. On the other hand, the dominant market power of the PR China results in a high supply chain risk. Therefore, the EU has declared these elements as critical raw materials of the highest category and plans a compulsory recycling share of 15% until 2030. Currently, no systematic recycling activities for RE magnets are operated on an industrial scale. In the present paper a concept for the extraction of RE magnets from rotors of HVAC compressors is presented. The focus is set on the thermal in-situ demagnetization by induction which is crucial for the disassembly of the magnets. This process ensures efficient heating to temperatures above the individual Curie temperatures so that interfering reaction forces are eliminated. Systematic test series are carried out based on an experimental set-up to identify the main process parameters and restrictions. The achieved results are analyzed and are evaluated regarding the transferability to a potential series process.<br

Analysis of Production Influences on the Transmission Efficiency of Wireless Power Transfer Systems - Kneidl, Maximilian; Fuß, Tobias; Weigelt, Michael; Masuch, Michael; Kühl, Alexander; Franke, Jörg (2023 IEEE Wireless Power Technology Conference and Expo, WPTCE 2023 - Proceedings, 2023)
Wireless power transfer (WPT) systems for electric vehicles are a more customer-friendly and convenient way of charging. Moreover, it seems to be a promising solution to increase the range of electric vehicles without having to use larger batteries. In addition to the positioning of the transmitter and receiver coils, the fabrication of the individual coils can also have a crucial impact on the overall efficiency of the transmission. The main objective of this paper is to use simulation results and practical validation to determine which manufacturing processes in the automated production of inductive power transmission systems affect both system efficiency and transmission performance for inductive charging applications. From the analysis of the process steps, the resulting manufacturing deviations are determined and evaluated. First, the manufacturing influences under real conditions are determined by performance measurements. The results obtained can be used to perform a simulative loss analysis of the components. It thus provides knowledge that can be used to design and monitor each process step. Keywords - Wireless Power Transfer, Manufacturing, Simulation, Efficiency)
CRIS-Team Scopus Importer:2023-09-22

Analysis of the effects of voids on crack initiation in solder joints of high-power LEDs - Xu, Ping; Ke, Rongge; Rauer, Miriam; Kaloudis, Michael; Franke, Jörg (2018 International Conference on Electronics Packaging and iMAPS All Asia Conference, ICEP-IAAC 2018, 2018)
In this investigation, the influences of voids on the crack initiation of the solder joints of high-power LED applications were studied. For the experimental analysis, power cycling tests with and without superimposed temperature cycling have been carried out. By using nondestructive test method of computed tomography (CT), the initiation and development of the cracks and failures during the aging tests were documented. In order to evaluate the different sizes, numbers and distributions of voids and their impact on the crack initiation in the solder joints, simulation approach with finite element method (FEM) has been applied. Based on the verified simulation model, further evaluations showed that the thickness of the solder joint had the strongest influence on the crack initiation, followed by the number of the voids. Critical areas of the solder joints in terms of crack formation have also been identified.
CRIS-Team Scopus Importer:2023-03-07
Keywords: crack initiation; creep strain; finite element analysis; high-power LED; power cycling test; reliability; voids

Analysis of the Rotary Cutting Process of Electrical Steel on Basis of a Toroidal Core Test - Hubert, Markus; Ziegler, Marco; Kutter, Simon; Schneider, Michael; Weigelt, Michael; Franke, Jörg; Hackert, Juergen; Mehlhorn, Marcus (2016 6th International Electric Drives Production Conference (E/DPC), 2016)
Rotary cutting of electrical steel strip is an innovative, but largely unexplored process. By state of the art a derivation of achievable process and product quality is not sufficiently possible yet. Within this publication, a series of experiments to rotary cut toroidal core specimens will be presented. With toroidal core tests on one the hand, the rotary cutting process itself is analyzed and on the other hand the results of the sample analysis reveal the process influences. Finally, a classification of the rotary cutting process into existing processing technologies of electrical steel strip is feasible with respect to its limits and possibilities.

Analysis of the Suitability of Inkjet-Printed Ag-Particle-Filled Inks for Use in Connections of Fine-Pitch Electrical Components - Voigt, Christian; Petersen, Matthias; Thielen, Nils; Utsch, Daniel; Häußler, Felix; Kirchberger, Manfred; Franke, Jörg (2023 46th International Spring Seminar on Electronics Technology (ISSE), 2023)
This paper explores a method for contacting Surface Mount Devices (SMD) using inkjet-printed media. A series of experiments is conducted to determine the needed layer thickness, drop size, and print parameters to facilitate adequate connections and evaluates the mechanical forces needed to break such a connection. Analysis of the joining partners using laser scan microscopy indicates necessary ink volumes between 75.1*10 3 and 800*10 3 μm 3 of connective media depending on the SMD size. The necessary amount of material is delivered to the substrate surface using inkjet printing, with the appropriate dwell voltage being determined in a separate experiment. After sintering for 10 minutes at 150°C, the inkjet-printed connections demonstrated electrical conduction in testing but showed 43% less resistance to shear forces, when compared to conventionally soldered connections, indicating a need for further optimization regarding the adhesive properties of the ink. The study provides insights for developing mechanically and electrically stable connections using inkjet-printed media, although further refinement is needed with regards to ink formulation and sintering tim

Analyzing and evaluating supplier carbon footprints in supply networks - Bodendorf, Frank; Dimitrov, Georgi; Franke, Jörg (Journal of Cleaner Production, 2022)
Green purchasing in green supply chain management (GSCM) literature plays an essential role in achieving carbon neutrality by seeking to eliminate CO2 emissions. Single organizations would, however, not aim at such a goal if it is to their economic detriment. GSCM research streams highlight that the successful implementation of environmental considerations leads to better economic performance in the long term. Therefore, this paper aims to identify and analyze suppliers that exhibit both environmental and economic success, indicating an effective and efficient realization of their sustainability measures. Given the long-term horizon of the research problem, we differentiate from previous microeconomic research by taking a macro perspective on sustainable supplier analysis, which investigates macroeconomic indicators focusing on firms' revenues. The above-described economic and environmental efficiency is analyzed in a multiple case study using sustainability reports from 66 OEM suppliers as well as data on their revenues and ratings on their carbon pollution measured by the Carbon Disclosure Project (CDP). First, a text mining inspired quantitative sustainable SWOT analysis is performed to evaluate the long-term strategy of organizations. A subsequent data envelopment analysis aims to identify efficient suppliers and causes for their efficiency. The overall results not only outline sustainable suppliers but also give insights into suppliers that may become sustainable in the future. We further show that large organizations struggle with meeting environmental expectations, whereas low-to-medium-sized suppliers tend to be more economically and environmentally efficient. Based on the results, we discuss implications both for management research and practice.
CRIS-Team Scopus Importer:2022-09-16
Keywords: Efficiency; Green supply chain management; Multi-method approach; Sustainability

Analyzing the Impact of Object Distances, Surface Textures and lnterferences on the Image Quality of Low-Cost RGB-D Consumer Cameras for the Use in lndustrial Applications - Schäffer, Eike; Beck, Alexander; Eberle, Jonathan; Metzner, Maximilian; Blank, Andreas; Seßner, Julian; Franke, Jörg (7. WGP-Jahreskongress, 2017)
Low-cost RGB-D cameras are currently used in applications in which their functionality and low price is preferred over accuracy. As there are many approaches for software optimization, the focus is primarily on improving the measurement setup to increase depth image quality of popular RGB-D sensors: we analyze the potentials of the Microsoft Kinect v1, Kinect v2 and Intel RealSense R200 as they differ in weight, power consumption, resolution and technology to acquire 3D-information resulting in different strengths and potentials. Initially, we briefly explain our measurement setup, the adjustable inputs and resulting outputs such as standard deviation of depth values, precision and error rate. Afterwards the results for each indicator, depending on camera sensors, surfaces, and distances between object and camera will be displayed. Based on our results, it is possible to quickly derive optimal scene surroundings to improve the depth image of a given 3D-camera before any programming effort is needed. A more accurate depth image improves subsequent image processing such as mapping, object or gesture tracking. This paper states the context in which a given camera or surface performs best depth quality, and how to link the results to industrial environments.

An Analysis of Black Energy 3, Crashoverride, and Trisis, Three Malware Approaches Targeting Operational Technology Systems - Geiger, Markus; Bauer, Jochen; Masuch, Michael; Franke, Jörg (2020 25th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA), 2020)
Connected factories offer more and more possibilities to bring business logic in the industrial related components like industrial control systems (ICS). These systems in the operational technology (OT) sector are usually harder to update and maintain compared to IT systems. In recent years, the number of cyberattacks that are specifically tailored to OT systems has increased. We analyzed BlackEnergy 3 (BE3), Crashoverride (CO), and Trisis (TS). After describing the occurrences of these attacks, we looked for similar strategies between these three approaches and propose promising methods to prevent such or similar attacks in the futur
Keywords: apt; malware; operational technology; security

An Analysis of Redundancy in High Volume High Mix Quality Testing Systems in Electronics Production - Voigt, Christian; Harnecker, Laura; Kirchberger, Manfred; Franke, Jörg (Proceedings of the International Spring Seminar on Electronics Technology, 2021)
Due to increasing demand regarding quality, quantity, and individualization of electronic products, requirements for automated quality testing systems in electronics production came to include the need for greater flexibility and speed. Sophisticated contemporary production lines of electronic assemblies can include automated solder paste, optical and X-ray inspection as well as in-circuit tests. With the ultimate goal of evaluating 100 % of solder joints of any given board, redundancy can occur regarding overlapping testing content. Whereas contemporary approaches to more efficient testing of electronic assemblies focus on the reduction of false calls using machine learning (ML), this paper analyzes the degree of redundancy between automated optical inspection (AOI) and X-ray inspection (AXI). We further explore possibilities for reducing the scope of testing to a necessary minimum, while still achieving full coverage of any given board. As communication of such analysis is of great importance in large-scale production facilities, a method of visualization is devised to utilize initial findings before a holistic approach can be implemented. Additionally, the transferability of PCB-level testing plans between product lines using machine-learning models is evaluated as a method of including implicit knowledge for new products.
CRIS-Team Scopus Importer:2021-09-10

An analysis of the effect of gravitational load on the energy consumption of industrial robots - Sinaga, Nazarudin; Paryanto, P.; Widyanto, Susilo A.; Rusnaldy, R.; Hetzner, Alexander; Franke, Jörg (6th CIRP Global Web Conference – Envisaging the future manufacturing, design, technologies and systems in innovation era (CIRPe 2018), 2018)
CRIS-Team WoS Importer:2019-06-28

An Analytical Approach to Thermal Design for Manufacturing in Mini Wave Soldering - Seidel, Reinhardt; Sippel, Marcel; Franke, Jörg (IEEE 71ST ELECTRONIC COMPONENTS AND TECHNOLOGY CONFERENCE (ECTC 2021), 2021)
CRIS-Team WoS Importer:2021-10-29

An Approach to Eddy Current Reduction in Laser Powder Bed Fused High Silicon Steel Considering Manufacturing Influences - Urban, Nikolaus; Masuch, Michael; Paduch, Jan; Franke, Jörg (2021 11TH INTERNATIONAL ELECTRIC DRIVES PRODUCTION CONFERENCE (EDPC), 2021)
CRIS-Team WoS Importer:2022-04-29

An Artificial Intelligence Approach for Online Energy Optimization of Flexible Manufacturing Systems - Bakakeu Ngassam, Romuald Jupiter; Bauer, Jochen; Tolksdorf, Schirin; Klos, Hans-Henning; Peschke, Jörn; Fehrle, Adrian; Eberlein, Werner; Bürner, Johannes; Brossog, Matthias; Jahn, Lars; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production IV, 2018)

An Automated Optical Inspection System for PIP Solder Joint Classification Using Convolutional Neural Networks - Schmidt, Konstantin; Rauchensteiner, Daniel; Voigt, Christian; Thielen, Nils; Bönig, Jochen; Beitinger, Gunter; Franke, Jörg (IEEE, 2021)
In the fields of electronics manufacturing, the application of through-hole devices is still required, as heat dissipation and high current carrying capacity plays an important role. To ensure the highest quality standards, these electronics production processes take a multitude of inspection processes into account. For the detection of error patterns regarding the quality of the solder connections, usually, high-end inspection machines are utilized in the industrial application. The Automated Optical Inspection is a commonly conducted process, using visible light and rule-based inspection routines, setup by process experts for the evaluation of the Region of Interest. The high overhead of creating and maintaining product-specific checking routines and machine acquisition leads to increased costs and severe dependency on expert know-how. A flexible inspection algorithm, implemented into low-cost equipment for image generation is expected to reduce acquisition and optimization costs, and lower dependency on expert knowledge and high-end machinery. In this contribution, we present a novel framework for the automatic, near real-time solder joint classification based on Convolutional Neural Networks, flexibly detecting, and classifying solder connections. We utilize existing Deep Learning architectures for detection and classification. The localization model utilizes a YOLO-architecture (you-only-look-once), learning feature inputs based on a supervised learning approach. Pseudo-labeling is carried out automatically by an anomaly detection model. The image generation is executed by an industrial low-cost camera and an industrial rack-PC. The developed prototype is integrated into the existing production infrastructure. The results indicate a satisfactory detection and classification of the investigated solder connections with the proposed system. Hence, this system represent an alternative to commercially available high-end inspection systems being used for an inline control of Pin-in-Paste and through-hole device solder connections.
Keywords: Location awareness; Deep learning; Image synthesis; Process control; Production; Optical imaging; Real-time systems; electronics production; optical quality inspection; machine learning; computer vision; Convolutional Neural Networks; pseudo-labeling

An autonomous robotic system for intralogistics assisted by distributed smart camera network for navigation - Zhang, Xu; Scholz, Michael; Reitelshöfer, Sebastian; Franke, Jörg (2018 IEEE 14TH INTERNATIONAL CONFERENCE ON AUTOMATION SCIENCE AND ENGINEERING (CASE), 2018)
CRIS-Team WoS Importer:2019-03-26

An Economic Solution for Localization of Autonomous Tow Trucks in a Mixed Indoor and Outdoor Environment Using a Node Based Approach - Zwingel, Maximilian; Herbert, Meike; Lieret, Markus; Schuderer, Peter; Franke, Jörg (Production at the leading edge of technology, 2020)
Flexible intralogistics solutions are basic components to enable classic manufacturing companies to compete in dynamic and global production networks. Developments in the field of autonomous road traffic technology and the increasing availability of cost-efficient sensors allow the economic use of autonomous systems in various industrial sectors. One of the subareas of autonomous systems with economic and technological potential is the intralogistics material supply with driverless transport systems. While the usage between buildings of such systems is not yet economically feasible, development of cost-efficient sensors from other markets are opening up new approaches in this area of operation. Localization and navigation, which must work seamlessly in mixed indoor and outdoor usage scenarios, are particularly critical to the success of autonomous systems. In this paper, a solution for the localization and navigation of autonomous driverless transport systems in a mixed indoor and outdoor scenario is proposed. It focuses on the use of cost-efficient sensors to enable a mostly infrastructure-independent localization of each system. The proposed solution is validated and a first approach for a dynamic fusion of localization data is don
Keywords: AGVs; Autonomous mobility; Cost-efficient sensors

An empirical investigation into intelligent cost analysis in purchasing - Bodendorf, Frank; Lutz, Manuel; Michelberger, Stefan; Franke, Jörg (Supply Chain Management-An International Journal, 2021)
Purpose Cost transparency is of central importance to reach a consensus between supply chain partners. The purpose of this paper is to contribute to the instrument of cost analysis which supports the link between buyers and suppliers. Design/methodology/approach Based on a detailed literature review in the area of cost analysis and purchasing, intelligent decision support systems for cost estimation are identified. Subsequently, expert interviews are conducted to determine the application possibilities for managers. The application potential is derived from the synthesis of motivation, identified applications and challenges in the industry. Management recommendations are to be derived by bringing together scientific and practical approaches in the industry. Findings On the one hand, the results of this study show that machine learning (ML) is a complex technology that poses many challenges for cost and purchasing managers. On the other hand, ML methods, especially in combination with expert knowledge and other analytical methods, offer immense added value for cost analysis in purchasing. Originality/value Digital transformation allows to facilitate the cost calculation process in purchasing decisions. In this context, the application of ML approaches has gained increased attention. While such approaches can lead to high cost reductions on the side of both suppliers and buyers, an intelligent cost analysis is very demanding.
Keywords: Purchasing; Manufacturing; Data analysis; Empirical study; Estimation; Cost management; Machine learning; Cost analysis; Cost estimation; Manufacturing industry

An Energy Ontology focusing on Demand Side Management in Smart Home - Schäfer, Franziska; Naser, Beate; Franke, Jörg (Advanced Engineering Forum 19, 2016)

A new Approach to increasing Energy Efficiency by utilizing Cyber-Physical Energy Systems - Bornschlegl, Martin; Drechsel, Michael; Kreitlein, Sven; Bregulla, Markus; Franke, Jörg (Proceedings of the Eleventh Workshop on Intelligent Solutions in Embedded Systems (WISES) 2013, IEEE Conference Proceedings, 2013)
Cyber-Physical Systems and Industry 4.0 topics are in the focus of research. Especially energy management systems can be improved with new opportunities due to interconnected systems. Cyber-Physical Energy Systems (CPES) will help to handle the use of volatile renewable energies and to realize intelligent shut down strategies. This paper gives an overview about current CPES research topics and shows an approach, which helps to reduce the energy consumption. The main aspects are avoidance of peak loads and reduction of base load from the perspective of a car manufacturer.

A New Approach to Integrate Value Stream Analysis into a Continuous Energy Efficiency Improvement Process - Drechsel, Michael; Bornschlegl, Martin; Spreng, Simon; Bregulla, Markus; Franke, Jörg (IECON 2013. 39th annual conference on IEEE Industrial Electronics Society, 2013)
Due to increasing energy costs and the demand to lower CO2 emissions in the production, companies try to integrate a continuous energy efficiency improvement process. By implementing the energy value stream analysis, an optimized improvement process can be established which leads to a more efficient production. This approach shows a practically optimized method. It enables a holistic analysis of the energy productivity and helps to identify and to realize sustainable solutions. Furthermore this structured improvement process leads to a higher transparency of energy consumers.
Keywords: energy efﬁciency; energy management; production planning; process planning; green design; green products; energy measurement; energy value stream analysis; continuous improvement process; CIP

A new development of micro-copper sinter material for high power electronics application - Schwarzer, Christian; Chew, Ly May; Stoll, Thomas; Franke, Jörg; Kaloudis, Michael (CIPS 2020 - 11th International Conference on Integrated Power Electronics Systems, 2020)
Copper is touted as an alternative die attach material. This study investigates the main parameters of a pressure sintering process using micro-scale copper sinter material as well as the behavior of the interconnection during thermal cycling by measuring the die shear strength and evaluating the microstructure of sintered copper layer. It was found that at 300°C a sintered joint is formed within 2 min. Furthermore, thermal cycling in a liquid-to-liquid shock test showed that only a slight decreased in the measured bonding strength decreased within the first 2000 cycles, therefore, the test has been extended by a further 1000 cycles.
CRIS-Team Scopus Importer:2021-04-19

A new production process for soft actuators and sensors based on dielectric elastomers intended for safe human robot interaction - Reitelshöfer, Sebastian; Landgraf, Maximilian; Gräf, Daniel; Bugert, Larissa; Franke, Jörg (2015 IEEE/SICE International Symposium on System Integration (SII), 2015)
Dielectric elastomers are the subject of intense research in material science. A large number of publications describe artificial muscles based on dielectric elastomer actuators as a promising alternative for an energy efficient, lightweight and flexible actuation architecture. Dielectric elastomer actuators could improve and extend the capabilities of robots in terms of soft kinematics for the direct physical interaction between humans and robots. They could also improve the dynamical performance and the eligibility for energy autarkic operation of robotic systems. Another field of application are dielectric elastomer sensors that can bear and detect large deformation. However, up to now dielectric elastomer actuators and sensors are not available on a large scale with reproducible characteristics. The focus of this contribution lies on a new automated production process using Aerosol-Jet-Printing for dielectric elastomer actuators and sensors with very favorable characteristics resulting from the additive manufacturing aiming at an improved availability of such sensors and actuators.
Keywords: deformation; electroactive polymer actuators; human-robot interaction; industrial robots; rapid prototyping (industrial); three-dimensional printing; additive manufacturing; aerosol-jet-printing; artificial muscles; automated production process; deformation detection; dielectric elastomer actuators; dielectric elastomer sensors; energy autarkic operation; energy efficient lightweight flexible actuation architecture; human-robot physical interaction; robot kinematics; robotic systems; soft actuators; soft sensors; Actuators; Dielectrics; Printing; Sensor phenomena and characterization; Service robots

An exergy-based analysis of temperature profiles for an over-pressure reflow oven technology - Esfandyari, Alireza; Landskrone, Torben; Syed Khaja, Aarief Hussain; Franke, Jörg (ASME 2015 International Mechanical Engineering Congress and Exposition, IMECE 2015, 2015)
In electronics assembly, the convection based soldering technologies in the production lines consumes massive resources and energy. The recent advancements in soldering technologies consume comparatively higher resources and needs to be optimized for resource efficient production which is also the motivation for the present work. This study is devoted to quantify the resource consumption and qualify this consumption through exergy flows in an over-pressure reflow technology as an energy intensive process in electronics manufacturing. The analysis implies on a big saving potential for energy consumption specifically during the over-pressure process which also defines the void reduction quality of solder joints. Exergy efficiency is the fraction of the work potential of the heat that is converted to work, and it illustrates the quality of consumed resources during the soldering oven process. Shortening the production lead-time, and increasing the production rate increase the efficiency of exergy and prevents wastage of usable energy. Furthermore, the set-up improvements for the temperature profiles are necessary, and the changes toward developing new technologies in pre-heating and over-pressure chamber zones are mandatory if a high efficiency of resources used is expected.

An Introduction of Two Different Modelica System Integration Concepts - Meinel, David; Faltus, Florian; Franke, Jörg (Procedia CIRP, 2016)
Abstract System engineers with a simulative system testing mission are facing the challenge of modeling the system's component-based architecture efficiently and modularly. Therefore, two different modeling concepts are proposed in this paper, which enable building and rebuilding a system modularly with the object-oriented modeling language Modelica. Moreover, the approach is capable of restructuring the model landscape towards co-simulation and Hardware-in-the-Loop (HiL). The concept is tested in a case study on trains.
Keywords: Modelica; System; Co-simulation; Modeling concept; Train; Hardware-in-the-Loop; Embedded; SimulationX

Annäherung an den Digitalen Wandel - Faltus, Florian; Fischer, Eva; Franke, Jörg (Handling, 2018)
Die Automatisierung von Produktionssystemen ist durch eine hohe technische Komplexität und starke Interdisziplinarität gekennzeichnet. Die Planung einer Industrieanlage erfordert die Koordination und Integration verschiedener Fachdisziplinen wie Mechanik, Prozess- und Elektrotechnik oder Software in Bezug auf das Vorgehen und die Arbeitsergebnisse. In diesem Zusammenhang stellt die Automatisierung als Bindeglied das korrekte Zusammenwirken der verschiedenen Disziplinen sicher. Durch den Ansatz Industrie 4.0 und der damit verbundenen Zunahme der IT-Durchdringung in der produzierenden Industrie steigt die Relevanz der Digitalisierung der Fertigung deutlich<br
Keywords: Industrie 4.0; Digitalisierung; VR; AR

An Ontology based Support for Smart Home Planning - Schäfer, Franziska; Zhang, Yixiao; Franke, Jörg (Advanced Engineering Forum 19, 2016)

A novel approach for data‑driven process and condition monitoring systems on the example of mill‑turn centers - Kißkalt, Dominik; Fleischmann, Hans; Kreitlein, Sven; Knott, Manuel; Franke, Jörg (Production Engineering, 2018)

A novel approach for thin-film Ag-sintering process through Aerosol Jet Printing in power electronics - Syed Khaja, Aarief Hussain; Hörber, Johannes; Gruber, Christopher; Franke, Jörg (20th European Microelectronics and Packaging Conference and Exhibition, EMPC 2015, 2015)
The growing demand for highly reliable and compact power electronic modules capable of operating at high switching frequencies and temperatures require optimized interconnection and packaging technologies. This holds true also for conventional electronics for usage at elevated temperatures, which allows additional options for miniaturization and high system integration without complicated cooling concepts. However, new materials and cost-effective manufacturing concepts are required. This contribution introduces a modified approach to produce thin-film silver sintered interconnections through Aerosol Jet Printing (AJP), which offers high degree of customization and design flexibility. The sintering process for silver nano-inks through AJP for power electronic die-Attach has been introduced. Power electronic assemblies had been constructed and high-Temperature shear tests up to 400°C had been performed to demonstrate the potential of the realized thin-film silver joints.

A novel approach of copper-ceramic-joints manufactured by selective laser melting - Stoll, Thomas; Kirstein, Matthias; Franke, Jörg (Proceedings of SPIE, 2019)
The processes of Additive Manufacturing (AM) are nowadays mostly used for mechanical and fluid components and have already made the transition from Rapid Prototyping (RP) to Rapid Manufacturing (RM). In the electronic industry however, mostly additive printing technologies are used to a large extent. This paper reveals a new process for the additive production of copper-ceramic composites using Selective Laser Melting (SLM). With this process, 3D metallizations can be produced on Al2O3 and spinel-like compounds, as known from Direct Copper Bonded (DBC) technology, can be formed by means of thermal post-treatments. Moreover, high adhesive strengths of up to 44 N/mm2, determined with shear testing, can be reached. The technology of melting copper or copper based powder on ceramic substrates can be used for example for power electronic applications for high current capabilities due to the possibility of manufacturing thick 3D metallizations without the occurrence of warpages as known from the DBC technology. In this study, extensive parameter analysis have been conducted with respect to laser power, laser velocity, hatching distance as well as focus shifting. On the other hand, the substrate temperature during the printing process was varied and post thermal treatments were applied in order to fully densify the metallization as well as form reaction layers between the ceramic-metal interface.<br

A Novel Concept for Unidirectional Communication With an Active Implant Based on Deliberately Produced Human Body Signals. - Benke, Elisabeth; Preis, Alexander; Schulz, Alisa; Reitelshöfer, Sebastian; Franke, Jörg (Annual International Conference of the IEEE Engineering in Medicine and Biology Society, 2022)
A new patient-friendly and discrete approach to build a unidirectional communication path with active implants based on deliberately produced human body signals is presented. The application for which this approach is intended is an artificial urinary sphincter implant, the closure mechanism of which is wirelessly actuated in the event of micturition need. Conventional implant communication methods can be associated with limitations regarding technological implementation and usability, and are used by medical professionals only. In order to enable patients to discretely and directly communicate with their implant without the need for an external handheld device, the feasibility of a communication approach based on manually applied 'knocking' signals on abdominal tissue is examined in the presented work. A gelatin-based phantom model is used to mimic vibro-acoustic properties of human soft tissue in vitro. A piezoelectric element and an electret microphone are applied as sensors for signal detection at the implantation site and are investigated with respect to their suitability for the intended application. Clinical Relevance- The presented implant communication method can contribute to urinary incontinence therapy by enabling patients to discretely and user-friendly actuate their artificial sphincter implant and can provide a basis for future research into new implant communication technologies.
Keywords: Urinary incontinence; medical implant; implant communication

A novel engineering process for spatial opto-mechatronic applications - Franke, Jörg; Zeitler, Jochen Tobias; Reitberger, Thomas (CIRP Annals - Manufacturing Technology, 2016)
Well-known advantages of optical data communication, like high-speed data transmissions and higher integration densities, are the main drivers for novel applications in the field of opto-electronics. A new innovative approach is to print polymer optical waveguides on spatial circuit carriers. This allows creating highly integrated devices that unify the characteristics of electro-optical circuits with the advantages of 3D-mechatronic integrated devices (MID). This paper describes the introduction of a novel engineering method that includes technology-specific processes for creating new spatial optomechatronic applications with the focus on printing technologies and computer-aided design.
Keywords: MID; optics; design; engineering; Aerosol-Jet printing; waveguide; manufacturing; opto-electronics

A novel method to reduce the harmonic currents in the residual earth fault current during a single phase to ground fault in compensated grids - Steglich, Michael; Löwe, Christopher; Bauernschmitt, Björn; Rehtanz, Christian; Böhm, Ralf; Franke, Jörg (Proceedings of 2019 IEEE PES Innovative Smart Grid Technologies Europe, ISGT-Europe 2019, 2019)
This paper presents a new approach to reduce the harmonic currents during a single phase to ground fault in a compensated grid. The reduction of the harmonic component in the fault current improves network stability and possibly prevents a blackout. A model has been simulated in Matlab-Simulink with multiple current sources working as compensation system in a 20 kV medium voltage example grid. The simulation results show that the harmonic distortion of the grid voltage has a significant influence on the magnitude of the fault current. That may lead to exceeding the extinguishing limit if the distortion is too high. With the presented method it is possible to significantly reduce the harmonic current without intervening the grounding of the transformer and the zero system. Furthermore, it is possible to place the system anywhere within the grid, which leads to a high degree of flexibility and facilitates upgrading.
CRIS-Team Scopus Importer:2019-12-13
Keywords: Grid stability; Power distribution faults; Power distribution reliability; Power quality; System services

An overhead docking and charging station for autonomous unmanned aircraft - Lieret, Markus; Wurmer, Florens; Hofmann, Christian; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2021)
Autonomous unmanned aircraft (UA) are currently gaining importance in various areas of application. In addition to their use in the field of surveying, inspection or fluid application, the focus is also on the transport of goods and the monitoring of factory premises. However, decisive disadvantage of commonly used UA is their short flight time, which typically ranges between approx. 10 and 45 minutes, depending on the design and payload. For the automated use of UA, it is not practical to manually change the battery between individual flights but automated solutions are required. The automated charging methods presented so far have in common that the UA approaches the landing platform vertically or at an angle from above and stands on the landing platform after completion. In this paper, we present a novel solution for the overhead charging of UA. Thereby the UA docks vertically to the charging station from below and is locked in the station. This saves floor space and allows the use of sensors attached to UA for information acquisition and environmental monitoring while charging. In addition to the charging station and the associated docking device attached to the UA, a camera-based method for localizing the charging station and for precise docking is presented. Finally, the docking and undocking process is evaluated in a series of experiments.
CRIS-Team Scopus Importer:2021-10-29

Ansatz zur integrativen Entwicklung räumlicher optomechatronischer Baugruppen - Zeitler, Jochen Tobias; Fischer, Christian; Franke, Jörg (Wissenschafts- und Industrieforum Intelligente Technische Systeme, 2015)
Keywords: MID; Optik; CAD; Design

Antriebstechnik im Zeitalter von Industrie 4.0 - wo stehen wir heute schon in der Forschung und Entwicklung? - Bogner, Eva; Abersfelder, Sandra; Franke, Jörg (Antriebstechnik, 2015)

Anwendung etablierter Vorgehensweisen der Softwareentwicklung in der produzierenden Industrie. Systematische Methoden - Auswahl bei der Digitalisierung - Selmaier, Andreas; Martens, Benedikt; Sjarov, Martin; Kuhn, Marlene; Herbert, Meike; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Digitalization projects are software projects. Less suitable for such projects are sequential planning methods often used in conventional project management, as application-specific requirements and interdependencies of facilities and IT systems considerably increase overall complexity. Therefore, this paper presents an approach for the systematic selection of suitable management methods for digitalization projects, which adds iterative procedures from software development to traditional project planning in the production environment.
CRIS-Team Scopus Importer:2020-07-31

Applicability of Security Standards for Operational Technology by SMEs and Large Enterprises - Wagner, Patrick; Hansch, Gerhard; Konrad, Christoph; John, Karl Heinz; Bauer, Jochen; Franke, Jörg (IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, 2020)
Establishing adequate cybersecurity for their operational technology (OT) is an existential challenge for manufacturing enterprises. Domain-specific security standards should provide essential support in this challenge. However, they cannot be implemented equally for enterprises of all sizes.We investigate to what extent domain-specific security standards for operational technology are applicable by small and medium-sized as well as large manufacturing enterprises, and how their individual need for action can be identified and addressed. We support our investigation with the results of two independent surveys among manufacturers about their needs for cybersecurity support.In the course of this investigation, we learned that most domain-specific security standards are well applicable to large enterprises. In contrast, small and medium-sized enterprises (SME) seek the support of security experts, who, for their part, are often struggling with a lack of experience in operational technology. To facilitate this cooperation, we provide an introduction for OT-and cybersecurity-experts to the respective basic concepts of their collaborators.
CRIS-Team Scopus Importer:2020-10-30
Keywords: OT; Production facilities; Security; SME; Standards

Application and comparison of analytic accelerated test-models for lifetime prediction of a novel contacting method - Spahr, Michael; Kreitlein, Sven; Haas, Raphael; Jaumann, Andreas; Gläßel, Tobias; Spreng, Simon; Franke, Jörg (2016 IEEE 62st Holm Conference, 2016)

Application and development of analytic accelerated test models for the lifetime prediction of a novel contacting method - Friedlein, Matthias; Spahr, Michael; Süß-Wolf, Robert; Franke, Jörg (7. WGP-Jahreskongress, 2017)

Application and Validation of an Existing Industry 4.0 Guideline for the Development of Specific Recommendations for Implementation - Bogner, Eva; Abersfelder, Sandra; Heyder, Andreas; Franke, Jörg (Advanced Materials Research, 2016)
From a technological point of view Industry 4.0 is already at an advanced stage. However, it still needs time to implement aspects of Industry 4.0 into the everyday life of project work. A major cause is the lack of methodologies in this area. Production-related areas must be prepared to identify the requirements and needs of Industry 4.0, right from the planning phase of the project. This paper describes an approach to create an Industry 4.0 Project-Roadmap as a base of important strategical decisions. Using the VDMA industry 4.0 toolbox, innovative ideas are developed, structured and finally prioritized considering effort and costs. The result is a roadmap, which allows the design of basic Industry 4.0 equipment of the project as well as to integrate further features as options. Due to different target groups and a very specific expectation the workshop procedure is modified to the already by the VDMA published guideline and presented in detail below.
Keywords: Coordination; Product development; Guideline

Application of design elements for an engineering community in a multi-sector engineering company - Götz, Johannes; Franke, Jörg; Mueller-Martin, Andreas; Forthaus, Markus; Grobholz, Boris (FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation, 2014)
The efficient and effective engineering of industrial plants has a high impact on the success of numerous companies. Core of engineering activities is to accurately cover the requirements of the customer and design and build a perfectly fitting solution. Due to the one-time character of these projects, time and money can be saved by a reuse of knowledge from former projects as well as a strong methodology to execute these complex projects. The need for an efficient exchange of knowledge and further development of engineering methods (e.g. resource planning, training concepts, cross-country collaboration) has been recognized by many companies on a top level. At the same time there is currently no consistent approach, how to involve the experience of a broad engineering community in the development and implementation of efficient methods. This work describes an approach which closes the gap between a grown "community of practice" and a top-down initiative for the development of engineering methods and structured knowledge exchange. It ensures the deep involvement of experienced engineers from a vivid community for exchange and feedback. Three formerly described design principles (stakeholders, infrastructure, content and activities) of a community-based initiative have been applied to in a multi-sector engineering company.
CRIS-Team Scopus Importer:2023-03-07

Application of Machine Learning for Product Batch Oriented Control of Production Processes - Meiners, Moritz; Mayr, Andreas; Thomsen, Maximilian; Franke, Jörg (Procedia CIRP, 2020)
The digitalization in manufacturing offers high potential for optimization in terms of quality and efficiency. In particular, machine learning techniques can be used to analyze data generated along the production chain for complex patterns. As the final product quality highly depends on interactions within the production chain, a process control system needs to consider all information of the supplied semi-finished products to achieve a continuously high quality. Using machine learning, this work presents a two-stage batch control system to optimize a batch process with high interdependencies between the delivered material, used equipment and process parameters concerning the final product quality.<br
Keywords: batch process; batch control; machine learning; production optimization

Application of the Technology Acceptance Model to an Intelligent Cost Estimation System: An Empirical Study in the Automotive Industry - Bodendorf, Frank; Franke, Jörg (2022)
Cost estimation methods are crucial to support inter- and intraorganizational cost management. Despite intense research on machine learning and deep learning for the prediction of costs, the acceptance of such models in practice remains unclear. The aim of this study is to evaluate the acceptance of an implemented deep learning-based cost estimation system. In an empirical study at a large Bavarian automotive manufacturer we use surveys to collect opinions and concerns from experts who regularly use the system. The evaluation is framed by the basic theories of the Technology Acceptance Model. The results from 50 questionnaires and qualitative participant observations show further development potentials of intelligent cost estimation systems in terms of perceived usefulness and user-friendliness. Building on our empirical findings we provide implications for both research and practice.<br
Keywords: Big Data and Analytics: Pathways to Maturity; technology acceptance model; intelligent cost estimation; emprical study; automotive industry

Application Scenarios of Artificial Intelligence in Electric Drives Production - Mayr, Andreas; Weigelt, Michael; Masuch, Michael; Meiners, Moritz; Hüttel, Franziska; Franke, Jörg (Procedia Manufacturing, Volume 24, 2018)
Artificial intelligence (AI) is the overall term for technologies used to build intelligent systems, no matter whether utilized in an industrial or private environment. However, hardly any AI-based approaches have been proposed for the increasingly important electric drives production yet. By identifying and presenting exemplary application scenarios for knowledge-based systems (KBS) and machine learning (ML), the paper serves as a starting point for further research in the respective fields. Among others, the systematic overview reveals that KBS are especially suited for supporting the planning of electric drives production systems, whereas ML-based approaches have great potential for optimizing single production processes.<br
Keywords: artificial intelligenceknowledge-based systemmachine learningintelligent systemselectric drives production

Approaches for additive manufacturing of 3D electronic applications - Hörber, Johannes; Glasschroeder, J.; Pfeffer, Michael; Schilp, J.; Zaeh, Michael; Franke, Jörg (Procedia CIRP, 2014)
Additive manufacturing processes typically used for mechanical parts can be combined with enhanced technologies for electronics production to enable a highly flexible manufacturing of personalized 3D electronic devices. To illustrate different approaches for implementing electrical and electronic functionality, conductive paths and electronic components were embedded in a powder bed printed substrate using an enhanced 3D printer. In addition, a modified Aerosol Jet printing process and assembly technologies adapted from the technology of Molded Interconnect Devices were applied to print circuit patterns and to electrically interconnect components on the surface of the 3D substrates. ©2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license.
CRIS-Team Scopus Importer:2023-03-07
Keywords: 3D electronic devices; Additive manufacturing; Aerosol Jet printing; Integration; Powder bed-based printing; Printed electronics

Approach for Advanced Mechanical Recycling Strategies of Rare Earth Magnets Applied in Traction Drives - Ihne, Thorsten; Hahn, Roman; Wieprecht, Nico; Franke, Jörg; Kühl, Alexander (Production at the Leading Edge of Technology, 2023)
Rare Earth (RE) Magnets are crucial for the green transition of the European Union (EU). This applies especially for e-mobility where RE magnets are used for highly efficient traction drives. Permanent magnetic motors offer the best efficiency, but the use of Rare Earth Elements (REEs) is related to several drawbacks. The magnets and the required raw materials are almost exclusively imported. This causes problems for European industry due to supply chain risks and continuously increasing prices. In addition, primary production is associated with a poor ecological footprint. Therefore, the EU has declared REs as critical raw materials with highest supply chain risk and plans a compulsory recycling share of 15% until 2030. Currently, no industrially applicable processes exist for systematic recovery of RE magnets. In this context the following paper should present approaches for an automated process chain starting with an end-of-life traction drive until the extracted and demagnetized magnets.<br
Keywords: Rare earth magnets; Recycling; Traction drives; Critical raw materials

Approach for the production chain of printed polymer optical waveguides–an overview - Loosen, Florian; Backhaus, Carsten; Zeitler, Jochen Tobias; Hoffmann, Gerd-Albert; Reitberger, Thomas; Lorenz, Lukas; Lindlein, Norbert; Franke, Jörg; Overmeyer, Ludger; Suttmann, Oliver; Wolter, Klaus-Jürgen; Bock, Karlheinz (Applied Optics, 2017)
Research for new production chains in the field of waveguide fabrication is a challenging task. Realizing a cost efficient manufacturing process allows integrating optical data communication in arbitrary structures, for example, the wing of an airplane or the body of a car. The production chain described in this paper contains the design, simulation, and fabrication process of printed polymer optical waveguides (POWs).

A privacy-preserving, sealed double-auction smart contract for Local Energy Markets - Funk, Felix; Teske, Franz; Franke, Jörg; Heider, Christian; Konig, Manuel; Soukup, Oliver (Workshop on Blockchain for Renewables Integration (BLORIN), 2022)
The continued proliferation of renewable energy sources (RES) in the residential sector enables private households to increasingly participate in the energy market. However, it also poses an infrastructural challenge as their spatial dispersion and the simultaneity of their energy generation increase the strain on the main grid. Local energy markets (LEMs) have been proposed to amend this effect by leveraging market dynamics to efficiently allocate privately generated energy in the immediate vicinity. Blockchain has been suggested as suitable information technology to reflect and support the decentralization and the parity characteristic of such LEMs. While some research on the topic has been conducted, concerns regarding anonymity in the proposed markets remain. In this study, we hence conceptualize a Blockchain-based LEM which expands on previous designs by introducing a one-time-address-based anonymization technique. The proposed concept also extends the double auction mechanisms of existing LEMs by a sealed offering protocol, providing information symmetry. The concept is prototypically implemented and validated using a Proof of Authority Ethereum network. It is shown that the implementation is sufficiently scalable for proposed LEM sizes.<br

A process model for systematically setting up the data basis for data-driven projects in manufacturing - Meier, Sven; Klarmann, Steffen; Thielen, Nils; Pfefferer, Christian; Kuhn, Marlene; Franke, Jörg (Journal of Manufacturing Systems, 2023)
In the rapidly advancing fields of Artificial Intelligence (AI) and Big Data, creating a robust and high-quality data foundation is a critical requirement for data-driven projects. However, the lack of a standard procedure for ensuring the existence of a sufficient and high-quality data basis often leads to misunderstandings, inefficiencies, and resource waste, resulting in a high risk of project failure. Existing methodologies often presuppose the availability of a data basis, which is a significant challenge, particularly in the manufacturing sector with its diverse and complex data sources. This challenge is further compounded by the interdisciplinary nature of these projects, where domain experts and data scientists with different expertise and vocabularies must collaborate. Addressing this gap, this paper introduces ML-SIPOC, a novel methodology for creating a standardized and high-quality data basis for data-driven projects. ML-SIPOC builds upon the traditional SIPOC analysis from the Six Sigma management system for operational excellence, adapted to meet the unique challenges of data-intensive projects. It provides a structured framework for systematically building a data foundation, facilitating effective communication between domain experts and data scientists. When applied in electronics manufacturing, ML-SIPOC proved efficient in creating a robust data basis, reducing time and cost overheads. This approach minimizes reliance on prior knowledge for data collection, opening up possibilities for broader AI and Big Data applications across various manufacturing sectors. The key innovation of this paper is the introduction of a first-of-its-kind methodology that provides a structured approach to building a data foundation for data-driven decision making in manufacturing.
Created from Fastlane, Scopus look-up
Keywords: Data mining; Electronics production; Industry 4.0; Intelligent manufacturing; Machine learning; Six Sigma

Architecture and low power management of a deep-tissue medical implant system powered by human body energy harvesting - Benke, Elisabeth; Fehrle, Adrian; Ollech, Johannes; Schrampfer, Simon; Franke, Jörg (BIODEVICES 2020 - 13th International Conference on Biomedical Electronics and Devices, Proceedings; Part of 13th International Joint Conference on Biomedical Engineering Systems and Technologies, BIOSTEC 2020, 2020)
Active mechatronic implants applied to provide therapy of insufficient bodily functions and acquisition of biomedical data are an emerging field in the context of Medicine 4.0. Wireless data transmission between the implant and out-body devices enables patients and health care professionals to access physiological data as well as take technical control and also allows for home monitoring solutions. Due to the limitations associated with primary batteries or conventional wireless power transferring methods in deep-tissue layers, human body energy harvesting is a promising alternative or complement for power supply. A high efficient power management in order to reduce the implanted device’s energy consumption is not only requested to effectively use the limited amounts of energy harvested but also contributes to extend implantation times and thus avoid invasive surgical procedures. This paper presents solution approaches for both software- and hardware-based low power management and storage options for active deep-tissue implants using hybrid energy storage systems and considering miniaturisation requirements of devices powered by energy harvesting.
CRIS-Team Scopus Importer:2020-04-28
Keywords: Energy Harvesting; Hybrid Energy Storage Systems; Implantable Medical Devices; Power Management

Architektur und Low-Power-Konzept für eine vernetzte Sensorplattform zur Erzeugung eines behaglichen und energieeffizienten Smart-Home-Umfeldes - Fehrle, Adrian; Benke, Elisabeth; Braun, Thomas; Dorscht, Felix; Hart, Manuel; Franke, Jörg (10. GMM-Fachtagung Energie Autonome Sensorsysteme EASS 2020, 2020)

A readiness check for regionalization of engineering - Schaeffler, Thomas; Kodes, Rudolf; Foehr, Matthias; Luder, Arndt; Götz, Johannes; Franke, Jörg (IECON Proceedings (Industrial Electronics Conference), 2014)
Regionalization of software and hardware engineering in international project business is a key driver for the success of multinational companies. These companies usually act as prime contractors and therefore have to execute large engineering projects across several countries. This requires a shift of the whole or at least a portion of their engineering value chain to a foreign country (regionalization). Since a shift of the value chain means a major change in the project execution process, a regionalization initiative is of high risk for the company. For that reason, we describe an approach to effectively check the extent to which a given company is ready for regionalization. The goal of this readiness check is to identify areas with need for action and preparatory work before starting a regionalization initiative. The check is structured alongside the fundamental questions as to why regionalization should be performed, what should be regionalized, who should do it, where regionalization should take place and which conditions apply. It provides management with a cockpit-like overview of the current state and addresses required action fields. By measuring the extent of regionalization readiness, important insight into the regionalization effort can be gained, such as the need for investment into the early phases and the required balance between all participating parties (stakeholders). Examples of practical use of the readiness check are presented and directions for further research are shown.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Engineering; Hardware; Project business; Readiness check; Regionalization; Software

A reference architecture for the development of socio-cyber-physical condition monitoring systems - Fleischmann, Hans; Kohl, Johannes; Franke, Jörg (2016 11th Systems of Systems Engineering Conference, SoSE 2016, 2016)
Cyber-Physical Production Systems (CPPS) help to cope with complexity and offer the computing platforms for sophisticated data analytics in smart factories. Nevertheless, in the operation of CPPS, the integration of tacit knowledge of the human as a maintainer has not been considered yet for the improvement of monitoring and diagnosis processes in production systems. The basic motivation for this publication is the development of a framework for technical maintenance systems in the context of a cyber-physical production environment, which conforms to the reference architectural model of Industry 4.0 (RAMI 4.0). The aim of the proposed solution is a systematic link between the information available by machine data acquisition with the tacit knowledge of humans to attain a high level of transparency in plant operation. The implementation is based on web technologies and platforms that are suitable for the implementation of CPPS and usability-optimized HMI. The validation of the system is accomplished by a diagnosis system with the energy consumption of a six-Axis handling unit in a demonstrator cell for mechatronic assemblies.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Condition Monitoring; OPC Unified Architecture; Reference Architecture

A reference architecture for the operationalization of machine learning models in manufacturing - Raffin, Tim; Reichenstein, Tobias; Werner, Jonas; Kühl, Alexander; Franke, Jörg (Procedia CIRP, 2022)
Inherent characteristics of machine learning algorithms such as their probabilistic nature, their reliance on large datasets as well as their need for constant retraining pose major challenges to the operationalization of machine learning models (MLOps) in the manufacturing domain. As such systems are known to quickly accumulate technical debt due to system-level interdependencies of code, data, and models, clear abstractions boundaries are mandatory. Therefore, this publication derives a systematic functional decomposition of an MLOps system tailored to the manufacturing industry into specific domains and contexts. Moreover, a concrete deployment view is provided, and possible future research directions are discussed.<br

Are we prepared for the Rise of Service Robots? - A Review on Acceptance Measurement - Merz, Nina; Franke, Jörg; Bodendorf, Freimut (The Human Side of Service Engineering, 2022)
Due to demographic change, technological innovations are needed to maintain standards of care. In addition, other service sectors face staffing challenges. Service robots are one technology that can address these challenges in this volatile, uncertain, complex, and ambiguous (VUCA) world. Since acceptance is necessary for the future success of these technologies, this literature review provides an overview on existing acceptance models for service robots. The identified models are structured using a robot classification to identify which domains are currently covered.

A robot motion planner for 6-DOF industrial robots based on the cell decomposition of the workspace - Ramer, Christina; Reitelshöfer, Sebastian; Franke, Jörg (IEEE ISR 2013, 2013)
This paper describes an autonomous robot motion planner for 6-DOF industrial robots based on the approximate cell decomposition of the workspace. Known obstacles lead to a hierarchical decomposition up to a predefined degree of the start cell which contains the whole robot workspace. A connectivity tree is searched for the shortest path from the start to the goal position for the Tool Center Point (TCP) of the robot. Center points and points between adjacent cells are used as interpolation points for the robot's path. All possible configurations are calculated for these points and checked for absence of collisions and compliance with kinematic constraints. Subsequently paths between possible configurations of interpolation points are checked for feasibility. If points cannot be reached artificial obstacles are constructed and the work space model is updated.
Keywords: cellular manufacturing; collision avoidance; industrial robots; interpolation; mobile robots; robot kinematics; trees (mathematics); 6-DOF industrial robots; TCP; adjacent cells; autonomous collision free path planning; autonomous robot motion planner; connectivity tree; interpolation points; kinematic constraints; path planning problem; tool center point; work space model; workspace cell decomposition; Automation; EMTP; Gold; Mars; Planning; Service robots; 6-DOF industrial robot; cell decomposition method; operational space planner; robot motion planner

Artificial Intelligence‐Based Assistance System for Visual Inspection of X‐ray Scatter Grids - Selmaier, Andreas; Kunz, David; Kißkalt, Dominik; Benaziz, Mohamed; Fürst, Jens; Franke, Jörg (Sensors, 2022)
Convolutional neural network (CNN)‐based approaches have recently led to major performance steps in visual recognition tasks. However, only a few industrial applications are described in the literature. In this paper, an object detection application for visual quality evaluation of X‐ray scatter grids is described and evaluated. To detect the small defects on the 4K input images, a sliding window approach is chosen. A special characteristic of the selected approach is the aggregation of overlapping prediction results by applying a 2D scalar field. The final system is able to detect 90% of the relevant defects, taking a precision score of 25% into account. A practical examination of the effectiveness elaborates the potential of the approach, improving the detection results of the inspection process by over 13%.
CRIS-Team Scopus Importer:2022-01-28
Keywords: Assistance system; Industrial artificial intelligence application; Object detection; Visual inspection; X‐ray scatter grid

Artificial muscles, made of dielectric elastomer actuators: A promising solution for inherently compliant future robots - Franke, Jörg (1st International Symposium on Soft Robotics in Germany, 2014)
Keywords: E|P

Artificial muscles, made of dielectric elastomer actuators - a promising solution for inherently compliant future robots - Yoo, In Seong; Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg (Springer Berlin Heidelberg, 2015)
The cutting-edge robotic technology can deal with a lot of complex tasks. However, one of the most challenging technological obstacles in robotics is the development of soft actuators. Remaining challenges in the field of drive technology can be overcome with innovative actuator concepts, for example dielectric elastomer actuators (DEAs). DEAs show numerous advantages in comparison to prevailing robotic actuators that are based on geared servomotors: They are formflexible, inherently compliant, can store and recuperate kinetic energy, feature high power-to-weight ratio and high energy density that is comparable to human skeletal muscles, and finally can be designed to perform natural motion patterns other than rotation. In this article, after a review on disadvantages of state-of-art robotic drives, which are stimulus for a research on the promising drive solution, benefits of DEAs will be presented with regard to the possibility of applications in soft robotics. Finally, the article will conclude with a brief report on the ongoing research effort at the Institute for Factory Automation and Production Systems (FAPS) with two major foci – the development of an automated manufacturing process for stacked DEAs and a lightweight control hardware.
CRIS-Team Scopus Importer:2023-03-07

Artificial muscles, made of dielectric elastomer actuators - A promising solution for inherently compliant future robots - Yoo, In Seong; Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg (Soft Robotics, 2015)
Keywords: artificial muscles; B|Mech; Künstliche Muskeln; Soft Robotics

Artificial neural networks for intelligent cost estimation – a contribution to strategic cost management in the manufacturing supply chain - Bodendorf, Frank; Merkl, Philipp; Franke, Jörg (International Journal of Production Research, 2021)
In today’s complex supply networks sharing information between buyers and suppliers is critical for sustainable competitive advantage. In particular, for both business partners, cost information is highly relevant in purchasing situations. According to empirical studies in literature, artificial neural networks (ANNs) are expected to have a great potential to reveal cost structures by machine learning (ML). In digitally enabled supply chains this information can contribute to cost reduction and operational excellence and lead to win-win situations in supplier relationship management. Nevertheless, authors do not thoroughly investigate how ANNs may support cost estimation for purchasing decisions. Based on a case study from the automotive industry, we evaluate ANNs regarding their capability to gain cost structure data. In an additional comparative study, we benchmark ANNs for cost estimation in purchasing against other promising ML algorithms. Thereby, we apply the cross-industry standard process model for data mining projects. The findings of the studies show that some ML algorithms outperform ANNs regarding accuracy. The research results give indications for choosing the ML approach that promises the best outcome for cost estimations and cost structure information to support decision-making in buyer–supplier relationships.
Keywords: Arfiticial neural networks; decision support; information sharing; purchasing; cost estimation; machine larning; automotive industry

ArUcoE: Enhanced ArUco Marker - Kedilioglu, Oguz; Bocco, Tomas Marcelo; Landesberger, Martin; Rizzo, Alessandro; Franke, Jörg (IEEE, 2021)
This paper presents a novel fiducial marker type called ArUcoE. It is obtained from a standard ArUco marker by enhancing it with a chessboard-like pattern. With our approach the pose estimation accuracy of any ArUco marker can easily be increased. Further methods to increase the accuracy are analyzed. By applying a subpixel algorithm to the corner regions we are able to locate the corner points within a pixel and overcome the restriction of pixel-level accuracy. A deep-learning-based super-resolution method is used to artificially increase the pixel density in the same regions. Additionally, the effect of using a single and a stereo camera setup on the accuracy is shown.
Keywords: Automation; Superresolution; Pose estimation; Cameras; Control system; Fiducial markers; computational efficiency; ArUco; 6DoF pose estimation; subpixel; deep learning; visual servoing; simulation

A simulation framework for theoretical analysis and virtual testing of longitudinal vibrations of trains - Meinel, David; Rast, Sebastian; Franke, Jörg (ACM International Conference Proceeding Series, 2018)
The vibrating among compartments in a train can cause safety relevant stresses in the mechanical couplers and thus negative effects on passengers' ride comfort. Detailed knowledge about the train dynamics is necessary for an eligible system design. In this paper, a multiple objective framework for simulating and analyzing longitudinal trainset kinetics is proposed. The framework uses an object-oriented modelling approach, featuring modular component models for e.g. the couplers, brakes, engines and the environmental resistance forces. A variable number of compartments can be adopted as well as flexible component composition and parameterization of the component models is possible. The framework will be validated by using characteristic operation scenarios in which the model parameters will be set to fit actual train behavior. The simulation results of the framework will be validated against experimental data and expertise. It will be proven that the simulated results meet the measured satisfyingly, regarding the occurring eigenfrequencies, amplitudes and damping characteristics. The vibrational behavior will be evaluated in terms of stress and displacement in the couplers as well as passenger comfort by analyzing the amplitudes and frequencies of the vibrations. The versatile applicability of the framework will be demonstrated by a successful reduction of vibrations through a modification of the excitation force behavior.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Dynamics; Longitudinal; Modelica.; Modeling; Multiple objective; Simulation framework; System simulation; Train; Validation

Assembly and Interconnection Technologies for MID based on Thermally Conductive Plastics for Heat Dissipation - Hörber, Johannes; Müller, Martin; Franke, Jörg; Ranft, Florian; Heinle, Christoph; Drummer, Dietmar (34th International Spring Seminar on Electronics Technology, 2011)
The present study aims to display new opportunities for Molded Interconnect Devices by using thermally conductive thermoplastics as substrate materials. Therefore, a polyamide 66 polymer was modified with aluminum oxide and gains thermal conductivity above 2 W/m·K. This compound was employed for three dimensional circuit carriers with integrated cooling fins manufactured by means of injection molding. Hot embossing tests indicate that it is possible to metallize the highly filled polymers at sufficient adhesion. For mounting and interconnecting electronic components by reflow soldering in a forced convection reflow soldering oven, a homogeneous temperature distribution, due to the thermal conductivity, enables enhanced process windows. Using test specimens with mounted LEDs, results of current research work are presented dealing with evaluating thermal footprints. The aim is to optimize manufacturing as well as component cooling. © 2011 IEEE.
UnivIS-Import:2015-04-16:Pub.2011.tech.FT.FT-KT.assemb

Assembly Molding for Resistant Media Tight Molded Interconnect Devices - Heinle, Martina; Goth, Christian; Drummer, Dietmar; Franke, Jörg (15th Int. Conference Polymeric Materials, 2012)
UnivIS-Import:2015-04-16:Pub.2012.tech.FT.FT-KT.assemb

Assessment of the Suitability of Selected Linear Actuators for the Implementation of the Load-Adaptive Biological Principle of Redundant Motion Generation - Bartz, Marcel; Jüttner, Michael; Halmos, Fabian; Uhlich, Elias; Klein, Max; Drumm, Patricia; Dreßler, Erkan; Martin, Sina; Walter, Jonas; Franke, Jörg; Wartzack, Sandro (Biomimetics, 2024)
The load-adaptive behavior of the muscles in the human musculoskeletal system offers great potential for minimizing resource and energy requirements in many technical systems, especially in drive technology and robotics. However, the lack of knowledge about suitable technical linear actuators that can reproduce the load-adaptive behavior of biological muscles in technology is a major reason for the lack of successful implementation of this biological principle. In this paper, therefore, the different types of linear actuators are investigated. The focus is particularly on artificial muscles and rope pulls. The study is based on literature, on the one hand, and on two physical demonstrators in the form of articulated robots, on the other hand. The studies show that ropes are currently the best way to imitate the load-adaptive behavior of the biological model in technology. This is especially illustrated in the context of this paper by the discussion of different advantages and disadvantages of the technical linear actuators, where ropes, among other things, have a good mechanical and control behavior, which is very advantageous for use in an adaptive system. Finally, the next steps for future research are outlined to conclude how ropes can be used as linear actuators to transfer load-adaptive lightweight design into technical applications.<br
Keywords: load-adaptive systems; musculoskeletal lightweight design; lightweight design robotics; linear actuators; redundant motion generation; tension chording; cable-driven robotics; rope pulls; artificial muscles

A standby strategy model for an energy efficient soldering oven machine - Esfandyari, Alireza; Javied, Tallal; Reissmann, Felix; Franke, Jörg (2016 IEEE Conference on Technologies for Sustainability, SusTech 2016, 2017)
The convection based soldering technologies in electronics assembly consume massive electrical energy. The recent advancements in soldering technologies consume comparatively higher resources and need to be optimized for resource efficient production which is also the motivation for the present work. This paper has an energy consumption reduction perspective by considering a detailed analysis of operation and system component interactions with respect to various use phase regimes of the reflow oven in electronics manufacturing. The methodology derives a detailed analysis and monitoring of all electrical energy intensive components of the oven. The soldering process phase requires a state based modification of electrical energy consumption for non-productive process times. An optimization model enables to define the optimal state within a given waiting time window on energy-minimal operating state trajectories in the oven. Using the modelling framework, a strategic decision making processes that make it possible to exploit the potential for energy consumption minimization of any non-productive times is introduced.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electronics production; energy efficiency; soldering oven; standby mode

A strategic approach to improve the development of use-oriented knowledge-based engineering configurators (KBEC) - Schäffer, Eike; Shafiee, Sara; Mayr, Andreas; Franke, Jörg (Procedia CIRP, 2021)
The high complexity of today's automation solutions often raises integration costs to an uneconomic level, particularly for small and medium-sized enterprises. Analyzing the total costs of automation solutions, engineering efforts account for the largest share. However, potentials for time and cost savings as well as quality improvements by reusing existing engineering knowledge are usually not exploited in industrial practice. In this context, knowledge-based configurators are the most popular expert systems and present an opportunity to automate the creation of customer-specific automation solutions. Especially for efficient knowledge reuse, constraint-based configurators seem suitable. However, existing methods for developing configurators focus on product configurators rather than on knowledge-based engineering configurators (KBEC). In addition, the necessary knowledge acquisition (KA) is still one of the major challenges in developing KBECs. Open fields of action include the definition of the optimal functional scope as well as the identification, prioritization, and selection of suitable knowledge sources. Another prerequisite represents the transparency of existing engineering processes and interests of all affected stakeholders. Therefore, this paper introduces a six-step approach enabling the development of use-oriented KBECs with the minimum required functional scope to reduce efforts for KA and thus overall development costs. Finally, the strategic approach is validated using the example of a KBEC for the concept planning of robot-based automation solutions.
Created from Fastlane, Scopus look-up
Keywords: automation; configurator; constraint-based; division of labor; engineering; KBEC; knowledge acquisition; knowledge-based; planning; robot

Asymmetric Optical Bus Coupler for Interruption-Free Short-Range Connections on Board and Module Level - Lorenz, Lukas; Nieweglowski, Krzysztof; Al-Husseini, Zaid; Neumann, Niels; Plettemeier, Dirk; Wolter, Klaus-Jürgen; Reitberger, Thomas; Franke, Jörg; Bock, Karlheinz (Journal of Lightwave Technology, 2017)
Keywords: Bus coupler; flexible structures; optical simulation; optical waveguide coupling; planar multimode waveguides

A systematic approach for planning, analyzing and evaluating internal material provision - Herbert, Meike; Heinlein, Pascal; Fuerst, Jens; Franke, Jörg (FAIM 2021, 2021)
CRIS-Team WoS Importer:2022-10-28

A System Embracing Observation of Different PTFE-Compounds in the Sealing Application of Rotary Manifolds - Müller, Julian; Illek, Rene; Michos, Gordana; Faust, Karsten; Hubert, Markus; Franke, Jörg (Applied Mechanics and Materials, 2015)
Due to the increase of product complexity, 5 axes machining centers are becoming more and more important. Rotary tables are usually chosen for the 4th and 5th axis. Additional hydraulic or pneumatic mounting clamps are often needed on these tables. The feeding of the required media is realized by a so-called rotary manifold. For this application, commonly several rotary seals are used to seal the transmitted media. Different sealing materials, based on the carrier polymer PTFE, have been examined during this research. In tribological model tests, friction and wear characteristics have been investigated during an oscillating movement under dry run conditions and equal load spectrums (surface pressure). The counter running surfaces were specific textured as a result of various machining processes to research the effects of possible micro- and macroscopic patterning on the sealing system. The tribological behavior of the analyzed combinations and the topography of the counter surfaces have been evaluated.

A system for human-in-the-loop simulation of industrial collaborative robot applications - Metzner, Maximilian; Utsch, Daniel; Walter, Matthias; Hofstetter, Christian; Ramer, Christina; Blank, Andreas; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2020)
As full automation is often not achievable in flexible production, collaborative robot systems offer potential for an increase in productivity for manual systems. These systems however pose great challenges concerning planning and engineering. We define main requirements for industrial human robot collaboration simulation. It is found that current simulation systems in research and industry cannot sufficiently support the digital planning of such systems. We introduce a framework for a human-in-the-loop system capable of simulation and virtual commissioning of industrial collaborative robot systems. For this, we implement a combined virtual reality, motion capturing and object tracking architecture into an industry standard robot simulation software. We validate our system on real use cases from power electronics production implementing real safety controllers and evaluate the fulfillment of the defined requirements.
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A System for Wireless Inductive Power Supply of Electric Vehicles while Driving Along the Route - Russer, Johannes A.; Haider, Michael; Weigelt, Michael; Becherer, Markus; Kahlert, Sebastian; Merz, Christoph; Schindler, Markus; Franke, Jörg; Russer, Peter (2017 7th International Electric Drives Production Conference (E|DPC), 2017)
A Moving Field Inductive Power Transfer (MFIPT) system concept for wireless inductive power supply in EjROAD traffic is described. In this system, inductive power receivers are arranged along routes of inductive power stations and in the vehicles. The MFIPT system provides the contactless energy transfer from an electrified road to the electrically driven vehicles during driving by dynamic inductive charging. In order to achieve a high efficiency, only the energy channels are activated for which the radiated energy can be received by energy recipient

Attention-based Image Compression in Sensor Assembly - Meier, Sven; Erkan, Acelya; Thielen, Nils; Klarmann, Steffen; Franke, Jörg (2022 IEEE 28th International Symposium for Design and Technology in Electronic Packaging, SIITME 2022 - Conference Proceedings, 2022)
The rapid development of the Industrial Internet of Things (IIoT) has led to an explosion in the amount of data to be transmitted and stored in the industrial sector. The investigated images are used in particular for quality control after individual process steps as part of Automated Optical Inspections (AOI). Image processing systems are among the key technologies here. Nevertheless, the storage and transmission of image data is still a major challenge for many companies. The use of AI-based image compression methods with higher quality performance compared to conventional methods becomes inevitable. Convolutional Neural Networks (CNNs) or Transformers are currently gaining ground in this area. However, the efficiency of these architectures has not yet been demonstrated in an industrial scenario. In this work, both a CNN- and a Transformer-based model with built-in Attention Mechanisms are trained with 8 bits per pixel (BPP) grayscale images generated in an industrial ultrasonic sensor production line. Even in the first test phase, in which only 2,000 images were used for model training, a compression rate of 0.162 BPP is achieved, far exceeding the quality of comparable JPEG-compressed images. When training the models with 100,000 images, the lowest BPP rate of 0.009 is achieved by the Transformer-based algorithm, resulting in an image quality that is sufficient for most quality assessment use cases. Thus, our results demonstrate the applicability and superiority of AI-based compression algorithms in industry. Their use leads not only to more efficient data transmission, but also to huge savings in storage space and costs for companies compared to traditional image compression methods.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Attention-based image compression; Big Data; Electronics Production; Machine Vision; Vision Transformer

Augmented Virtuality Data Annotation And Human-In-The-Loop Refinement For RGBD Data In Industrial Bin-Picking Scenarios - Blank, Andreas; Baier, Lukas; Zwingel, Maximilian; Franke, Jörg (Proceedings of the Conference on Production Systems and Logistics, 2022)
Beyond conventional automated tasks, autonomous robot capabilities aside to human cognitive skills are gaining importance. This comprises goods commissioning and material supply in intralogistics as well as material feeding and assembly operations in production. Deep learning-based computer vision is considered as enabler for autonomy. Currently, the effort to generate specific datasets is challenging. Adaptation of new components often also results in downtimes. The objective of this paper is to propose an augmented virtuality (AV) based RGBD data annotation and refinement method. The approach reduces required effort in initial dataset generation to enable prior system commissioning and enables dataset quality improvement up to operational readiness during ramp-up. In addition, remote fault intervention through a teleoperation interface is provided to increase operational system availability. Several components within a real-world experimental bin-picking setup serve for evaluation. The results are quantified by comparison to established annotation methods and through known evaluation metrics for pose estimation in bin-picking scenarios. The results enable to derive accurate and more time-efficient data annotation for different algorithms. The AV approach shows a noticeable reduction in required effort and timespan for annotation as well as dataset refinement.<br
Keywords: Data Annotation; Augmented Virtuality; Human-in-the-Loop; Machine Learning; Bin-Picking

Augmented Virtuality Input Demonstration Refinement Improving Hybrid Manipulation Learning for Bin Picking - Blank, Andreas; Zikeli, Lukas; Reitelshöfer, Sebastian; Karlidag, Engin; Franke, Jörg (Lecture Notes in Mechanical Engineering, 2023)
Beyond conventional automated tasks, autonomous robot capabilities aside human cognitive skills are gaining importance in industrial applications. Although machine learning is a major enabler of autonomous robots, system adaptation remains challenging and time-consuming. The objective of this research work is to propose and evaluate an augmented virtuality-based input demonstration refinement method improving hybrid manipulation learning for industrial bin picking. To this end, deep reinforcement and imitation learning are combined to shorten required adaptation timespans to new components and changing scenarios. The method covers initial learning and dataset tuning during ramp-up as well as fault intervention and dataset refinement. For evaluation standard industrial components and systems serve within a real-world experimental bin picking setup utilizing an articulated robot. As part of the quantitative evaluation, the method is benchmarked against conventional learning methods. As a result, required annotation efforts for successful object grasping are reduced. Thereby, final grasping success rates are increased. Implementation samples are available on: https://github.com/FAU-FAPS/hybrid_manipulationlearning_unity3dros
CRIS-Team Scopus Importer:2022-11-25
Keywords: Bin picking; Human-in-the-loop; Machine learning; Mixed reality

A universal analysis tool for process-and energy-optimization of insulation processes in the production of electric drives - Hofmann, Benjamin; Buchfelner, Mathias; Hirschbrunn, Johannes; Franke, Jörg (2015 5th International Conference on Electric Drives Production, EDPC 2015 - Proceedings, 2015)
The process of deciding on an appropriate impregnation method is quite challenging due to the high amount of distinct methods and rising requirements, especially within traction drive production. At the Institute for Factory Automation and Production Systems in Nuremberg (FAPS), a simulation tool for the analysis of impregnation processes for electric drives was developed. This tool enables an accurate and detailed analysis of impregnation and curing methods using a material flow simulation to evaluate the level of economy. The primary focus lies on process capabilities (e.g. lead times, work in process, output), economic efficiency and energy consumption. This paper presents the process of defining the necessary constraints and requirements for a tool in order to display and compare several currently available impregnation processes. The actual tool based on commonly used value stream analysis software provides universal adaptability to existing impregnation units as well as improvement scenarios. Additionally, an energy analysis extension of the software developed at FAPS was integrated into the analysis tool. The extension allows readily importing actual recorded energy data and thus predicting the overall energy consumption in a clear and precise manner. To aid the analysis of the simulation results, automated evaluation was integrated into the tool. This includes a visual presentation of the results, a fully automated graphical interpretation of the data and the possibility of comparing several scenarios at once. The tool aims to simplify the analysis of impregnation scenarios. It is suitable for performing a detailed comparison of real impregnation processes as well as future, improved methods and alternatives that are still under development.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Flow Simulation; Impregnation; Insulation

Auswahl industrieller Serviceplattformen - Fuchs, Jonathan; Hartner, Fabian; Brossog, Matthias; Franke, Jörg (wt Werkstattstechnik - Online, 2019)
Der Einsatz von Serviceplattformen im industriellen Kontext verspricht Unterstützung und Optimierung im Produktionsalltag durch leistungsfähige cloudbasierte Anwendungen. Die Vielzahl der Plattformlösungen führt zu einer heterogenen, intransparenten Marktfülle und resultiert in einer komplexen Entscheidungsfindung für die Anwender. Dieser Beitrag zeigt relevante Unterscheidungskriterien auf und bietet zugleich eine Hilfestellung zur anwendungsfallorientierten Plattformauswahl.<br
Keywords: Industrie 4.0; Smart Services; Internet

Auswahl industrieller Serviceplattformen - Methodisches Vorgehen zur Auswahl geeigneter cloudbasierter IIoT-Plattformlösungen - Fuchs, Jonathan; Hartner, Fabian; Brossog, Matthias; Franke, Jörg (wt Werkstattstechnik - Online, 2019)
Service platforms in an industrial context promise to support and improve everyday production through powerful cloud-based applications. The multitude of platform solutions, however, makes the market heterogeneous and intransparent, resulting in a complex decision-making process for users. This article points out relevant differentiation criteria while offering support for a platform selection to suit many different use cases.
CRIS-Team Scopus Importer:2020-02-21

Automated and Flexible Production of Inductive Charging Systems as an Enabler for the Breakthrough of Electric Mobility - Weigelt, Michael; Masuch, Michael; Mayr, Andreas; Seefried, Johannes; Kühl, Alexander; Franke, Jörg (Advances in Production Research, 2018)

Automated Domain Adaptation in Tool Condition Monitoring using Generative Adversarial Networks - Lutz, Benjamin; Kißkalt, Dominik; Regulin, Daniel; Aybar, Burak; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2021)
Microscopy is commonly used in machining to study the effects of tool wear. In modern tool condition monitoring systems, the analytical capabilities are further enhanced by machine learning, allowing for automated segmentation of the various visible defects. The prevailing challenge, however, is the divergence among different use cases, as the visual properties of cutting tool images are influenced by many domain-specific factors such as the type of the cutting tool, the respective machining process, and the image acquisition unit. Thus, we propose the usage of automated domain adaptation so that existing training data from source domains can be used effectively to train segmentation models for novel target domains, while minimizing the need for newly labelled data. This is achieved through image-to-image translation using generative adversarial networks, which generate synthetic images with similar visual characteristics as the target domain based on existing masks of the source domains. Our validation shows that with as few as ten labelled images from the target domain, a sufficient prediction performance of 0.72 mIoU can be achieved when tested on unseen images from the target domain. This corresponds to a reduction of manual labelling efforts by two-thirds compared to conventional labelling and training methods. Thus, by adapting existing data, prediction performance is increased while expensive data generation is minimized.
CRIS-Team Scopus Importer:2021-10-29
Keywords: Domain Adaptation; Generative Adversarial Networks; Image Segmentation; Image-to-Image translation; Smart Manufacturing; Tool Condition Monitoring

Automated electrical characterization setup for aerosol-jet-printed dielectric elastomer transducers - Martin, Sina; Kaßner, Sebastian; Bruns, Arne; Schärfe, Paul; Reitelshöfer, Sebastian; Franke, Jörg (Online international conference on Electromechanically Active Polymer (EAP) transducers & artificial muscles, 2021)
For the production of stacked and individually shaped dielectric elastomer (DE) transducers, the aerosol-jet-printing had been chosen and further developed at our institute. This printing technology allows the alternating direct deposition of thin layers of either silicone dielectrics or reduced graphene particle electrodes. As the layers are deposited line-wise the surface quality is an issue that has to be considered to obtain constant and predictable electro-mechanical parameters. Typically the characterization of those material systems is performed following the standards for DE testing by Carpi, et al. Based on this established standard we built up our test bench for mechanical and electrical multi-analysis of the printed DE. Furthermore, the setup has been automated to make DE characterization more precise and to facilitate the comparison of a large number of samples in order to create a validation routine to optimize the production process. To allow precise positioning of the specimen the four-axis have been motorized and the program interfaces are used to align the generated information with other measurable parameters such as environmental conditions or timestamps.<br
Keywords: Dielectric elastomer transducers; automated measurement; testing standards; system charcterization

Automated Exploration, Capture and Photogrammetric Reconstruction of Interiors Using An Autonomous Unmanned Aircraft - Lieret, Markus; Kogan, Vladyslav; Hofmann, Christian; Franke, Jörg (2021 IEEE International Conference on Mechatronics and Automation, ICMA 2021, 2021)
Digital environment models are gaining importance in various fields of application. High-resolution digital models of the current environment structure can facilitate planning manufacturing plants or allow monitoring construction processes precisely. While systems for the fully automated capturing of terrain structures are already in use in outdoor areas, the digitisation process in indoor areas is usually carried out manually. Since global navigation satellite systems are not available in complex indoor areas, other solutions for robust and precise autonomous localization and navigation have to be used and validated. Furthermore, it is more intricate to ensure that all required areas and structures are taken into account with sufficient accuracy during the capture process. Within this paper, we present a fully automated system for data acquisition and digitisation of complex indoor environments. Using an autonomous unmanned aircraft equipped with a suitable sensor system, intelligent algorithms for navigation, exploration and photogrammetric reconstruction, a previously unknown environment is autonomously explored and a three-dimensional model is reconstructed. Extending the related research, we demonstrate that also within indoor environments unmanned aircraft are applicable for the autonomous acquisition of images for photogrammetric reconstruction. Within the evaluation, we validate the functionality of the overall system and the accuracy of the resulting point clouds of the environment.
CRIS-Team Scopus Importer:2021-10-01
Keywords: autonomous unmanned aircraft; environment perception; photogrammetry; robot navigation

Automated generation of human-machine interfaces in electric drives manufacturing - Fleischmann, Hans; Brossog, Matthias; Beck, Maximilian; Franke, Jörg (2017 7th International Electric Drives Production Conference, EDPC 2017 - Proceedings, 2018)
In industrial software development for electric drives manufacturing, human-machine interface (HMD-engineering is a time-consuming process, as concepts like service-oriented architectures and aspects of interoperability are not prevailed yet. The Reference Architectural Model Industrie 4.0 aims to solve this challenge and serve companies as a framework for developing future products and business models by defining unified software structures. In this context, we develop and validate a concept for the realization of highly configurable, adaptable HMI for visualizing and monitoring of discrete production plants based on the technologies OPC Unified Architecture and AutomationML. By conforming to the Reference Architectural Model Industrie 4.0, the fast adoption to various application scenarios and the efficiency enhancement in corresponding development processes is possible.
CRIS-Team Scopus Importer:2023-03-07
Keywords: AutomationML; Human-machine Interfaces; node.js; Open Platform Communications Unified Architecture; Reference Architectural Model Industrie 4.0; Web technology

Automated in-house transportation of small load carriers with autonomous unmanned aerial vehicles - Lieret, Markus; Kogan, Vladyslav; Döll, Sebastian; Franke, Jörg (2019 IEEE 15th International Conference on Automation Science and Engineering (CASE), 2019)
Within the last years, the application of unmanned aerial vehicles (UAV) in the delivery and logistics sector has become focus of various research projects. This can be traced back to the fact that UAVs allow a flexible and fast transportation and extend the flow of materials by the third dimension. While the feasibility of outdoor transports with UAVs has already been shown in the scope of pilot projects the indoor transportation of cargo with UAVs lags behind. This can be ascribed to both legal restrictions and missing technical innovations. To advance the technical implementation we developed a scalable hard and a software system for the flexible and automated in-house transportation of small load carriers with autonomous UAVs. In addition, a tracking system that is both suitable for the basic tracking of a UAV during the flight and for the precise tracking required to pick up and set down the cargo is presented. The presented system is based on a newly developed cargo drone including a lightweight and energy-efficient load handling device. Its features and setup will be highlighted before the resulting integral system is evaluated within a paradigmatic use case whereby a prepared cargo is autonomously picked up, transported and delivered to a predefined destinatio

Automated magnet assembly for large PM synchronous machines with integrated permanent magnets - Joseph, Eric; Tremel, Jan; Hofmann, Benjamin; Meyer, Alexander Wilhelm; Franke, Jörg; Eschrich, Sebastian (2013 3rd International Electric Drives Production Conference, EDPC 2013, 2013)
The manufacturing of large synchronous motors and generators with integrated permanent magnets currently contains a large amount of manual processes as well for handling as assembly. Magnets have to be separated and prepared for insertion manually, bearing a high risk for injuries. Due to increasing batch sizes in industrial as well as in traction drive applications, the efficiency of these processes has to be examined and developed towards an automated assembly. The paper presents an approach for partially automated manufacturing of a wide portfolio of rotors for drives on a single assembly machine. © 2013 IEEE.
Keywords: Assembly; Magnets

Automated Optical Inspection of Soldering Connections in Power Electronics Production Using Convolutional Neural Networks - Metzner, Maximilian; Fiebag, Daniel; Mayr, Andreas; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Automated Optimization of Complex Three-dimensional Robot Trajectories - Buschhaus, Arnd; Franke, Jörg; Reitinger, Peter (2nd IEEE International Conference on Control, Automation and Robotics, 2016)
Jointed-arm robots can be used for a broad variety of tasks. Thereby the planning of complex three-dimensional trajectories can be very time consuming. This is especially true, if a defined movement of the work-piece relative to a process-tool is required. For such tasks, the trajectory programming is greatly supported by 3D-kinematic simulation tools. However, the dynamic attributes of the real robot are unconsidered by this way of programming. Geometric discontinuities within the process path lead to abrupt changes of the Tool Center Point (TCP) orientation, which results in infinite values for acceleration and deceleration of the robot axis. Adjacent process planes, which share the same edges but have different angles of their surface normals, require an abrupt change of the work-piece orientation relative to the tool. This results in irregularities of the robot movements. To overcome this problem, a method and system for an automated trajectory optimization of complex 3D-robot movements is developed at the FAPS institute. Thereby in critical areas of the process pathway a continuous and defined pre- or post-rotation of the work-piece relative to the tool is achieved, considering process and robot specific boundary conditions. Further algorithms have been developed, which enable an automated control of the process equipment and an automatic generation of non-process relevant trajectory segments for a TCP reorientation. In addition, the velocity parameters of the robot movements are automatically modified. By this way of proceeding, a steady movement speed of the tool relative to process planes and a smoother robot movement is guaranteed, which has been as well validated by first experiments.
Keywords: B|Mech

Automated reasoning and knowledge inference on OPC UA information models - Bakakeu, Jupiter; Brossog, Matthias; Zeitler, Jochen Tobias; Franke, Jörg; Tolksdorf, S.; Klos, H.; Peschke, J. (Proceedings - 2019 IEEE International Conference on Industrial Cyber Physical Systems, ICPS 2019, 2019)
The fourth industrial revolution demands flexibility, adaptability, transparency and semantic interoperability. Within the German Industry 4.0 initiative, the Reference Architecture Model Industrie 4.0 (RAMI4.0) has recently been standardized and OPC Unified Architecture (OPC UA) is listed as the sole recommendation for implementation of a communication layer. Even though OPC UA helps bridge the interoperability gap at the automation level, its semantic has not yet been formally defined and an efficient automated reasoning and knowledge inference on the OPC UA address space is therefore not yet possible. This paper addresses this issue by presenting a solution to infer knowledge from OPC UA information models. By analyzing and comparing the semantic expressiveness of the OPC UA address space with semantic knowledge representation formalisms such as RDF and OWL, we derived and implemented a solution to transform an OPC UA information model into an RDF-Graph expressing an OWL Ontology. Using the generated ontology, we were able to run a true reasoning task directly on the OPC UA address space. In this paper, the developed approach is conveniently validated on various case studies involving online factory reconfiguration, intelligent energy management, and human-machine interfaces.
CRIS-Team Scopus Importer:2019-08-30
Keywords: Industrie 4.0; Knowledge Inference; OPC UA; Sementic Web; SPARQL.

Automatische Identifikation mittels RFID - Rückverfolgbarkeit von Fertigungshilfsmitteln in der Produktion von Hochleistungsröntgenstrahlern - Herbert, Meike; Stirm, Julian; Hofmann, Christian; Fürst, Jens; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2022)
Modern technologies are a key enabler for the automatic identification of objects in production to ensure quality-related traceability of components or manufacturing equipment. This article presents a possible solution for the traceability of equipment, tools and measuring devices by applying a RFID system in the production of high-performance X-ray tubes and discusses the results of durability analysis.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Identification Systems; RFID; Lifetime; Traceability; X-Ray

Automatisierte Pfadgenerierung und Kollisionsüberwachung für Sechsachs-Industrieroboter durch 3D-kameragestützte Umgebungserfassung - Ramer, Christina; Reitelshöfer, Sebastian; Franke, Jörg (Kongress Automation, 2013)

Automatisierung von Overheadprozessen: Erschließung von Effizienzpotentialen für Industrie 4.0 - Bogner, Eva; Götz, Johannes; Fleischmann, Hans; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Die aktuelle Diskussion zu Industrie 4.0 fokussiert sich insbesondere auf die zahlreichen Befähigertechnologien und deren mögliche Anwendung in den Unternehmen. Die eigentlichen Nutzenpotentiale für die Unternehmen werden dabei jedoch häufig vernachlässigt. Der vorliegende Beitrag stellt dazu eine Diskussionsgrundlage dar und geht insbesondere auf die Effizienzpotentiale durch die schrittweise Automatisierung von der eigentlichen Produktion vorgelagerten Arbeitsschritten ein. Denn erst wenn es möglich ist, diese Overheadprozesse zu automatisieren und mit der Produktion zu vernetzen, kann durch eine deutliche Effizienzsteigerung in der Produktion erzielt werden.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Nutzenpotentiale; Overheadprozesse; Automatisierung; Effizienzsteigerung; Industrie 4.0; Cyber-physische Systeme

Automatization of the Cable-Routing-Process within the Automated Production of Wiring Systems - Heisler, Paul; Steinmetz, Patrick; Yoo, In Seong; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production III, 2017)
The wiring system is one of the most important and one of the most expensive part of modern passenger vehicles. It ́s production is done manually to nearly 100% since the early years of car manufacturing. Until today it wasn ́t possible to automatize these cost-intensive step of the car production in an effective and cost efficient way. This paper shows how the routing process of the wiring harness as a part of the whole production process can be automatized with easy and cost efficient production methods. Collaborative robots and 3D-printed prototypes of cable grippers were used to treat with the complexity of the job and to finally create a sustainable and cost efficient production system. Further the routing concept has been brought to a prototypical production cell which has been tested in various routing experiments at the institute’s laboratory. Finally, a discussion of the results brings up the strengths and weaknesses of the concept and shows possible solution
Keywords: Wiring Harness Production; Automated Wire Handling; Cost Efficient Production; 3D-Printing of Grippers; Wire Routing; Industry 4.0 in the Wiring Harness Production; MMI-Robotics in the Wiring Harness Production

A Wireless Angle and Position Tracking Concept for Live Data Control of Advanced, Semi-Automated Manufacturing Processes - Lipka, Melanie; Meinel, David; Müller, Stefan; Sippel, Erik; Franke, Jörg; Vossiek, Martin (Sensors, 2020)
Despite recent industrial automation advances, small series production still requires a considerable amount of manual work, and training,and monitoring of workers is consuming a significant amount of time and manpower. Adopting live monitoring of the stages in manual production, along with the comprehensive representation of production steps, may help resolve this problem. For ergonomic live support, the overall system presented in this paper combines localization, torque control, and a rotation counter in a novel approach to monitor of semi-automated manufacturing processes. A major challenge in this context is tracking, especially hand-guided tools, without the disruptions and restrictions necessary with rigid position encoders. In this paper, a promising measurement concept involving wireless wave-based sensors for close-range position tracking in industrial surroundings is proposed. By using simple beacons, the major share of processing is transferred to fixed nodes, allowing for reduced hardware size and power consumption for the wireless mobile units. This requires designated localization approaches relying on only relative phase information, similar to the proposed Kalman-filter-based-beam-tracking approach. Measurement results show a beam-tracking accuracy of about 0.58 ∘" role="presentation">∘ in azimuth and 0.89 ∘" role="presentation">∘ in elevation, resulting in an overall tracking accuracy of about 3.18 cm.
Keywords: industrial automation; worker information system; localization; FMCW; angle-of-arrival

Bag Bin-Picking Based on an Adjustable, Sensor-Integrated Suction Gripper - Blank, Andreas; Seßner, Julian; Yoo, In Seong; Metzner, Maximilian; Deichsel, Felix; Diercks, Tobias; Eberlein, David; Felden, Dominik; Leser, Alexander; Franke, Jörg (Tagungsband des 3. Kongresses Montage Handhabung Industrieroboter, 2018)
Robot-based separation and handling of flexible packaging bags filled with small individual parts is a special challenge in the field of bin-picking. Reasons for this are challenges in the field of orientation and position recognition of bags within the extraction station, the damage-free and reliable handling of these bags as well as a precise bag deposition inside a target region (e.g. final packaging). This paper presents an adjustable, sensor-integrated suction gripper optimized for bag bin-picking. The multi-modal sensing hardware used for the gripper is based on weight force measurement and vacuum sensors for the separation. Additional ultrasonic sensors are used to reduce the risk to damage the bag's content and the gripper. The performed tests proof the feasibility of the approach in terms of robustness and achievable cycle times.
Keywords: robot-based bag bin-picking; sensor integrated gripper

Baustoff-integrierte Flächenheizung (BiFH): Abschlussbericht - Braun, Thomas; Franke, Jörg (Fraunhofer IRB Verlag, 2019)
Keywords: Plasmabeschichtung; Thermische Behaglichkeit; Oberflächenfunktionalisierung

Bedarf und Konzeptvorstellung des Forschungsprojekts ROBOTOP für einen webbasierten Konfigurator für den Massenmarkt - Schäffer, Eike; Thi, Kim; Franke, Jörg (2020)
The development of a modular, internet-based and open robot platform (ROBOTOP) serves to open up the mass market for robots in service and manufacturing applications. Through an intelligent standardization and reuse of software, hardware and peripheral components as well as the significant reduction of offer and engineering costs, significant cost reductions can be achieved in the planning and design of industrial robotics solutions. Lizenz: CC BY-NC-ND 4.0<br

Bedeutung der zukünftigen Produktion kundenindividueller Produkte in Losgröße 1 - Bogner, Eva; Löwen, Ulrich; Franke, Jörg (Vernetzt – Dezentral – Kollaborativ. Interdisziplinäre Perspektiven zur Zukunft der Wertschöpfung, 2018)
Im Zuge der vierten industriellen Revolution wird immer stärker das Thema einer zukünftigen Produktion kundenindividueller Produkte in Losgröße 1 diskutiert. Ob dies tatsächlich pauschal eine Produktionsstrategie für die produzierende Industrie darstellt, gilt es zu analysieren. Hierzu muss zum einen die Vielfalt der produzierenden Industrie und die aktuelle Rolle von Individualisierung betrachtet werden. Zum anderen gilt es die bestehenden Konzepte der Individualisierung zu identifizieren und zu analysieren. Außerdem wird eine exemplarische Veränderung in der Vergangenheit bezüglich der Umsetzung von Individualisierung betrachtet, als Grundlage für die weitere Diskussion. Denn erst auf Basis einer ganzheitlichen Betrachtung kann eine These formuliert werden, inwiefern eine derartige Konsolidierung überhaupt denkbar ist.
Keywords: Produktindividualisierung; Losgröße 1; Industrie 4.0

Beeinflussung der optischen Eigenschaften von Polymer Optischen Wellenleitern durch das Druckpfad-Design - Backhaus, Carsten; Lindlein, Norbert; Zeitler, Jochen Tobias; Franke, Jörg (DGaO Proceedings, 2019)
In der DFG-finanzierten Forschergruppe OPTAVER (Optische Aufbau- und Verbindungstechnik für baugruppenintegrierte Bussysteme) wurden erfolgreich Lichtwellenleiter mittels eines Aerosol-Druck-Verfahrens mit vorheriger Konditionierung hergestellt sowie ein virtuelles Abbild der gesamten Prozesskette erstellt. Dieses Verfahren ermöglicht nahezu beliebige Druckpfade, sodass dies den Weg frei macht für neue Realisationen von optischen Buskopplungen.Ein nun möglicher Druckpfad ist jedoch nicht zwangsweise eine Verbesserung in Bezug auf die optischen Eigenschaften des Lichtwellenleiters. Die besondere Geometrie des Querschnitts der Polymer Optischen Wellenleiter (POW) beeinflusst das Design des Druckpfades. Ein Beispiel dafür ist der minimale Radius, den eine Kurve haben darf, damit kein Licht aus dem Wellenleiter auskoppelt. Um nun Vorschriften für das Druckpfad-Design ableiten zu können, benötigt es einer Charakterisierung der POWs bezüglich verschiedenster Druckpfade. Diese Charakterisierung wird vorgestellt und die daraus abgeleiteten Druckpfad-Design Vorschriften aufgezeigt. Des Weiteren werden neue Realisierungsmöglichkeiten von optischen Buskopplungen vorgestellt
Keywords: Additive Fertigung; Polymer Optische Wellenleiter; optische Eigenschaften

Benchmark of automated machine learning with state-of-the-art image segmentation algorithms for tool condition monitoring - Lutz, Benjamin; Reisch, Raven; Kißkalt, Dominik; Avci, Behiye; Regulin, Daniel; Knoll, Alois; Franke, Jörg (Procedia Manufacturing, 2020)
In condition monitoring of cutting inserts for machine tools, vision-based solutions enable detailed wear pattern analysis. Besides the main failure modes of flank wear and tool breakage, other defects, such as chipping, grooves, and build-up-edges, can be detected and quantified. However, manual analysis of the images is time consuming and traditional machine vision systems have limited capabilities adapting to changing situations, such as different insert types. As a result, robust machine learning techniques are researched to support the process of classifying images and detecting defects through image segmentation. For the latter, a variety of highly optimized networks exists. Still, these networks require tuning by machine learning experts. In contrast, automated machine learning is a recent trend that greatly reduces these efforts through automated network selection and hyperparameter optimization. In this study, automated machine learning is compared with manually trained segmentation networks on the example of tool condition monitoring. To achieve this, a heterogeneous dataset of over 200 industrial cutting tool images is recorded and evaluated. Comparing the manually trained segmentation networks to the automated machine learning framework, it is determined that the automated machine learning solution is easier to handle, faster to train and achieves better accuracies than other approaches.<br
Keywords: Tool Condition Monitoring; Image Segmentation; Machine Learning; Automated Machine Learning

Benefits of an universal Winding Machine - Mahr, Alexander; Masuch, Michael; Franke, Jörg (Electric Drives Production Conference 2016, 2016)
Keywords: Coil winding; E|DRIVE; E|DRIVE; Elektromaschinenbau; Füllfaktor; Effizienz; Flexible Production; flexible production concepts; Human-Machine Interface (HMI); Industrie 4.0; winding of HF-litz wires; Wires

Bewertung neuer Fertigungskonzepte für hohe Stückzahlen in der E-Maschinenfertigung - Bogner, Eva; Bickel, Benjamin; Franke, Jörg (Vorausschau und Technologieplanung, 2015)
Der zunehmende Einsatz von Elektromotoren im Automobilbereich stellt neue Anforderungen an deren Bauweise und die notwendigen Produktionsprozesse. Um auf die wachsenden Absatzpotentiale im Bereich der Elektrofahrzeuge reagieren zu können, bedarf es nicht nur einer Produktoptimierung hinsichtlich Bauraum, Gewicht und Wirkungsgrad, sondern vor allem auch automatisierter, stückzahl- und variantenflexibler Produktionstechnologien. Jedoch entscheiden sich Unternehmen aufgrund der hohen notwendigen Investitionskosten trotz der Potentiale häufig gegen die Investition in neue Technologien. Aus diesem Grund beschäftigt sich dieser Beitrag mit der ganzheitlichen Bewertung neuer Fertigungskonzepte für die E-Maschinenfertigung. Damit soll sowohl ein Wirtschaftlichkeitsvergleich hinsichtlich hoher Stückzahlen ermöglicht als auch die technologischen Nutzenpotentiale der Konzepte nachvollziehbar offengelegt werden. Herausforderung ist dabei neben der Strukturierung der komplexen Entscheidungssituation die Erarbeitung eines Gesamtsystems zur Integration und Darstellung der Gesamtergebnisse, das eine gezielte Abwägung zwischen den Potentialen und Kosten neuer Technologien ermöglicht. Zur Durchführung der Bewertung dient ein Tool, das die entwickelte Bewertungsmethodik entsprechend abbildet und einen iterativen Bewertungsprozess sowie die Simulation verschiedener Technologieszenarien ermöglicht. Anwendungsbeispiel ist die Optimierung der Statorfertigung der BMW AG im Rahmen eines öffentlich geförderten Forschungsprojektes. Anhand der gewonnenen Erkenntnisse und deren Interpretation wird eine Handlungsempfehlung für die zukünftige flexible weitestgehend vollautomatisierte Produktion von E-Maschinen abgeleitet.
Keywords: Technologiebewertung; Elektromotoren; Fertigungstechnologien

Bitte ein Taxi! Autonomer Materialtransport in der Intralogistik. - Scholz, Michael; Franke, Jörg (Handling, 2015)

Blind Path Obstacle Detector using Smartphone Camera and Line Laser Emitter - Saffoury, Rimon; Blank, Peter; Seßner, Julian; Groh, Benjamin; Martindale, Christine; Dorschky, Eva; Franke, Jörg; Eskofier, Björn (International Conference on Technology and Innovation in Sports, Health and Wellbeing (TISHW), 2016)

Blockchain architecture for automotive traceability - Kuhn, Marlene; Funk, Felix; Franke, Jörg (8th CIRP Conference of Assembly Technology and Systems, 2021)
The automotive value chain comprises a complex manufacturing network, which encompasses several departments, companies, and even countries. In the age of electrification and autonomous driving, the quality and transparency requirements are rising, in particular for electric and electronic components, which contribute to safety-critical functionalities. In this research, we analyze the traceability requirements and liability implications for the automotive manufacturing network. A key component in preventing safety and quality deficiencies in manufacturing processes is a state-of-the-art traceability system. Accordingly, we propose a blockchain-based traceability architecture to achieve the aspired level of transparency and process security. The proposed blockchain architecture processes manufacturing data entries and defines blockchain nodes, access, as well as consensus algorithm and transaction logic. An Ethereum-based blockchain demonstrator validates the architecture by implementing the logic for automotive product configuration and process sequencing based on the semi-fungible ERC 1155 token, the proof of authority consensus, and an automotive product token smart contract.
Keywords: Traceability; Blockchain; Automotive; ERC 1155 token; Smart contract

Blockchain-based application for the traceability of complex assembly structures - Kuhn, Marlene; Funk, Felix; Zhang, Guanlai; Franke, Jörg (Journal of Manufacturing Systems, 2021)
Production processes are becoming increasingly complex and decentralized, spanning across multiple manufacturing areas, factories, and even countries. Thereby is the development of a holistic and data-continuous traceability system, which provides transparency of records for the entire manufacturing flow from raw materials to the final product, one of the main challenges. While some solutions already address traceability issues in supply chain management and manufacturing, customized and volatile industries, in which each product features a unique configuration, are still lacking appropriate models and proofs of concept. In this research, we develop a decentralized blockchain application called TokenTrail, which focuses on the specific traceability requirements of multi-hierarchical assembly structures. The proposed blockchain architecture is based on a consortium Ethereum network and a Proof of Authority consensus, which delivers a trusted and shared database within an economic processing framework. To overcome the challenges of managing liaison transformations, we develop an assembly token manager based on the semi-fungible ERC 1155 token, which enables a direct representation of complex assembly processes and structures containing unique parts and batches within one smart contract. A user-friendly front-end application simplifies the querying of the recorded traceability data and visualizes existing dependencies. <br
Keywords: Traceability; dApp; Blockchain; ERC 1155; Assembly; Smart manufacturing; Graph model

Blockchain Enabled Traceability – Securing Process Quality in Manufacturing Chains in the Age of Autonomous Driving - Kuhn, Marlene; Nguyen, Huong Giang; Otten, Heiner; Franke, Jörg (2018 IEEE International Conference on Technology Management, Operations and Decisions (ICTMOD), 2019)

Bringing the new class of cable-driven parallel robots to the world of industrial cyber-physical systems based on RAMI 4.0 - Walter, Jonas; Grau, Simon; Raczok, Tobias; Reitelshofer, Sebastian; Franke, Jörg (2022 IEEE 5th International Conference on Industrial Cyber-Physical Systems (ICPS), 2022)

Building Blocks for Digitally Integrated Process Chains in PBF-Based Additive Manufacturing - Sjarov, Martin; Ceriani, N.; Lechler, Tobias; Franke, Jörg (Production at the leading edge of technology, 2020)
As applications of Additive Manufacturing (AM) extend from rapid prototyping into series production, new challenges of digital information integration arise. In order to obtain transparency of overall costs and part quality, the relevant information of each process step needs to be gathered from different sources and combined in a meaningful way. Thus, a digitally integrated process chain can provide added value for manufacturers and their clients. This paper proposes building blocks for digitally integrated process chains in the context of powder bed fusion (PBF) based AM to form a basis for transparency of cost and quality. Solving requirements for the end-to-end digital chain leads into challenges of acquiring, storing, processing and routing information. Related technologies comprise domain-specific software, enterprise integration patterns, database and semantic technologies. The mapping of these enablers onto the AM chain leads to a target architecture that forms the fundament for future investigation
Keywords: Additive manufacturing; Digital process chain; Application integration; Industry 4.0

Building Cyber-Physical Systems - A Smart BuildingUse Case - Bakakeu Ngassam, Romuald Jupiter; Schäfer, Franziska; Bauer, Jochen; Michl, Markus; Franke, Jörg (Smart Cities: Foundations, Principles, and Applications, 2017)
This chapter explores the concept of smart home and smart building based on internet-of-things (IoT) and cyber-physical system (CPS) technologies. By reviewing the challenges of the smart home vision, it highlights that CPS-based smart environments are best suited to support the integration of heterogeneous devices with different application domains and architectures. To illustrate the concept of a CPS-based smart building installation with self-configuration and self-organization abilities, the chapter presents implementation of smart home use cases based on the paradigms of "Industry 4.0". In addition, it also analyzes and discusses the performance of the implemented prototype. The concept of "Industry 4.0" provides a vision for the application of CPS in industrial automation. The chapter then proposes an approach based on OPC unified architecture (OPC UA) that supports self-description by using a common ontology and self-organization through the use of multi-agent systems (MAS) theory.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Cyber-physical ecosystem; Industrial automation; Internet-of-things; Multi-agent systems theory; OPC unified architecture; Smart building; Smart home use cases

Business Analytics in Strategic Purchasing: Identifying and Evaluating Similarities in Supplier Documents - Bodendorf, Frank; Wytopil, Benedict; Franke, Jörg (Applied Artificial Intelligence, 2021)
The increasing digitalization in the automotive industry is influencing the structure of the traditional value chain and calls for the handling of large amounts of data to remain competitive in a constantly changing environment. This results in new challenges for purchasing management, which has to cope with agile integration of service providers as well as interorganizational process automation using electronic data exchange platforms. This work analyzes the electronic document stream on supplier management platforms by proposing an automated text mining framework. Both textual components, e. g., requests for information and offers, and narrative material, e. g., financial and calculation data, are being analyzed by topic modeling and descriptive statistics. The methodological approach is introduced and illustrated by the use case of service provider documents in purchasing processes. The results reveal financial potential for purchasing and generally contribute to supply chain cost management.

Cabin Interior Components as Substrate Material for Printed Electrical Circuits - Ischdonat, Nils; Gräf, Daniel; Gleine, Wolfgang; Dreyer, Christian; Bauer, Monika; Franke, Jörg (International Workshop on Aircraft System Technologies AST2017, 2017)

Cable-driven robotic joint for automated hammering Seilrobotergelenk für automatisiertes Hämmern - Walter, Jonas; Nemoto, Takeru; Bachmann, Christian; Gerlich, Matthias; Reitelshöfer, Sebastian; Franke, Jörg (wt Werkstattstechnik - Online, 2022)
Conventional robots are vulnerable to high impact loads due to the configuration of rigid joints and fragile gears. This paper shows that a robotic joint based on a novel topology with three active and three passive cables can cope with impact loads as they occur in machining tasks such as hammering.
Created from Fastlane, Scopus look-up

Calculation of the Copper Filling Factor of Electric Traction Drives including Graphical Representation - Riedel, Andreas; Roessert, Alexander; Kühl, Alexander; Franke, Jörg (2019 22nd International Conference on Electrical Machines and Systems, ICEMS 2019, 2019)
In order to achieve a higher power density of electric traction drives, one significant optimisation variable is the copper filling factor. A self-developed MATLAB program makes it possible to graphically display the filling factors known from the literature in order to visualize optimisation potentials. It is possible to display quadratic, rectangular as well as trapezoidal slot geometrics with round wires or flat conductors. The different wire diameters and their isolation can be chosen from IEC 60317-0-1 or can be inserted manually. After entering the required parameters, the slot geometry is fitted with round or flat conductors according to the principle of the orthocyclic winding scheme. By varying the slot geometry and the wire parameters, the optimum filling factor for different applications can be determined graphically and mathematically, taking into account the assembly air.
CRIS-Team Scopus Importer:2020-02-21
Keywords: electric traction drives; filling factors; MATLAB; optimisation; tool

CAMERA-BASED FALL DETECTION SYSTEM WITH THE SERVICE ROBOT SANBOT ELF - Bauer, Jochen; Gründel, Lennarth; Seßner, Julian; Meiners, Moritz; Lieret, Markus; Lechler, Tobias; Konrad, Christoph; Franke, Jörg (Smart Public Building 2018Conference Proceedings, 2018)

Case Based Reasoning im Qualitätsmanagement - Schäfer, Franziska; Brandmeier, Markus Andreas; Kuhn, Marlene; Franke, Jörg; Otten, Heiner (wt Werkstattstechnik - Online, 2017)
Die Entwicklung zur Losgröße1 im Rahmen der Industrie4.0 stellt das Qualitätsmanagement vor neue Herausforderungen. Klassische Qualitätsmethoden, welche unter anderem Tests und statistische Analysen umfassen, können in der individualisierten Produktion zur Prozessoptimierung nicht einfach übernommen werden. In diesem Fachbeitrag werden die Möglichkeiten des „Case Based Reasoning“ als neues Qualitätswerkzeug zur Prozessoptimierung für kleine Losgrößen analysiert und an einem Beispiel in der Elektronikfertigung konkretisiert.
Keywords: Qualitätsmanagement; Industrie 4.0; Informationsmanagement

Challenges and Opportunities of Software-Based Production Planning and Control for Engineer-to-Order Manufacturing - Bründl, Patrick; Stoidner, Micha; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (Advances in Production Management Systems. Production Management Systems for Responsible Manufacturing, Service, and Logistics Futures. APMS 2023, 2023)
This article aims to explore the use and implementation of software-based production planning and control (PPC) systems in variant-rich manufacturing environments, specifically in the engineer-to-order (ETO) manufacturing. A systematic literature review is conducted to identify, which PPC tools are used in the ETO business, how they should be implemented and the benefits and challenges associated with their use. The results indicate that such systems can be technically and economically advantageous, however application of existing systems off-the shelf solutions is not recommended. The literature suggests a structured approach for the implementation considering critical success factors and a well-planned process supported by the proposed framework. Most of the systems analyzed in the literature are Enterprise Resource Planning systems. Furthermore, the findings show four different areas of positive effects for the companies, such as improved production efficiency, improved planning efficiency, improved decision-making, and increased competitiveness. Additionally, five different kinds of challenges can be observed: Knowledge and expertise, Cost and resource management, Process and system flexibility, Data management and IT infrastructure and System usability and applicability.<br
Keywords: Engineer-to-Order; Production planning and control; Systematic literature review; Implementation guidelines