Challenges in bonding processes in the production of electric motors - von Lindenfels, Johannes; Ziegler, Marco; Kneidl, Maximilian; Kühl, Alexander; Franke, Jörg (Proceedings of the 9th Congress of the German Academic Association for Production Technology (WGP), 2019)
In an effort to meet climate protection targets, countries around the world are promoting electro mobility. As a result of market growth, the worldwide production capacities for electric motors for traction drives is going to expand significantly. Besides, the existing technology must be adapted to automotive-specific life cycle requirements. On the product side, the electric machine has to reach maximum power densities in order to keep the required limitations of space and weight. Furthermore, a fully automated production process is essential to achieve high output rates and required quality standards. The application of new adhesives and bonding processes implements product-relevant properties in the production of components for electric motors. Moreover, the selection of adhesive systems and process parameters is crucial for cost-efficient and high quality manufacturing processes in mass production. In the production of permanent magnet synchronous machines, adhesives are used for joining of lamination stacks, fixation of magnets and the overall assembling of stator housings.The paper analyses and evaluates different adhesive systems in terms of their product and process capability using two cases of application. The results serve as a starting point for further automated process development and reveal the challenges of the adhesive application in production technology for electric motors.
Keywords: Quality; Security; Mobility

Challenges in Cost-effective Automated Detection of Enameled Flat Wires in the Context of Robot-based Stator Manipulation - Vogel, Alexander; Morello, Andreas; Mahr, Alexander; Franke, Jörg; Kühl, Alexander (2022 12th International Electric Drives Production Conference (EDPC), 2022)
Especially in the production of electric drives, highly efficient drives in new use cases are needed to reach global climate targets. To obtain maximum motor power with minimal motor weight, it is necessary to fill the stator slots with a maximum of copper. In the past, the round wire has been the state of the art. However, with increasing efficiency expectations, round wires cannot reach the performance targets anymore. Form coils, also known as hairpins, are one common technology with higher fill factors. In addition, winding processes with endless flat or rectangle wires are currently in development and could fulfill the demand for electric drives in the future. Accompanied by new joining solutions, this technology could lower the production cost on the one hand and reduce the contacting spots with potentially increased contacting resistance on the other hand. One challenge in the automation of their winding and joining is a fully automated process chain, starting with the winding process and ending with end-of-line testing. One thing, all process steps have in common is the requirement to detect the position of the wires with high precision. This detection is fundamental to subsequent steps, performed by smart robot-based machines.<br
Keywords: wire detection; flat wire; image recognition; stator manipulation; stator manufacturing automation; electric drives production

Challenges in gesture control of robots based on multi-degree of freedom movement recognition with dielectric elastomer sensors - Landgraf, Maximilian; Reitelshöfer, Sebastian; Yoo, In Seong; Franke, Jörg (5th International Conference on Electromechanically Active Polymer & Transducers & Artificial Muscles (EuroEAP), 2016)
Keywords: artificial muscles; Biomechatronik; DEA; EAP; Electromyography (EMG); Robot Control

Challenges in the Manufacturing of Hairpin Windings and Application Opportunities of Infrared Lasers for the Contacting Process - Gläßel, Tobias; Seefried, Johannes; Franke, Jörg (2017 7th International Electric Drives Production Conference (EDPC), 2017)

Challenges of Contacting Processes for Thin Copper Flat Wires in the Context of Electromechanical Engineering - Seefried, Johannes; Mahr, Alexander; Weigelt, Michael; Kühl, Alexander; Franke, Jörg (2021 11TH INTERNATIONAL ELECTRIC DRIVES PRODUCTION CONFERENCE (EDPC), 2021)
CRIS-Team WoS Importer:2022-04-29

Challenges of the Hairpin Technology for Production Techniques - Riedel, Andreas; Masuch, Michael; Weigelt, Michael; Gläßel, Tobias; Kühl, Alexander; Reinstein, Sebastian; Franke, Jörg (2018 21st International Conference on Electrical Machines and Systems (ICEMS), 2018)
The electrification of the drive train of passenger cars is currently undergoing an evolution from windings previously drawn in, which are known from industrially used electrical machines, to windings specially tailored to the requirements of mobile electric traction. A main trend is the use of pluggable shape windings, so-called hairpins. In order to fully exploit the economic advantages of this winding, elaborated production concepts and strategies are required. Due to the novelty and the currently ongoing innovation of these type of windings, the differentiated manufacturing possibilities per process step have not yet been fully defined. In view of the economic efficiency, high process speeds with increasing process reliability play a major role. The aim of this paper is to show a process chain of hairpin technology that is as universally valid as possible, to name the different alternatives for each process step and to explain their characteristic
Keywords: Wires; Windings; Insulation; Manufacturing automation; Production systems; Conductors; Hairpin; Process Chain; Production Technologies

Challenges of the Miniaturization in the Electronics Production on the example of 01005 Components - Niemann, Jens; Härter, Stefan; Kästle, Christopher; Franke, Jörg (Tagungsband des 2. Kongresses Montage Handhabung Industrieroboter, 2017)

Chances of the Application of Multi-Domain Simulation Tools in the Field of Train System Engineering - Meinel, David; Paryanto, Paryanto; Franke, Jörg (Proceedings of the 24th FAIM Conference, 2014)
Complex mechatronic systems, such as modern trains, demand interdisciplinary software tools in order to test systems as a whole and predict operational behavior. Caused by the intention of cost savings and pushing the market launch time, computer-aided modelling and simulating of the behavior of single devices, such as thermal effects, stresses, deformations and also electrical state variables, have long since become state-of-the-art. This method leads to well-matured products. The component integration into the system as a whole, however, often causes trouble due to the lack of computer and software assistance. Furthermore, the diverse engineering fields do not have the expertise to collaborate. Therefore, joined system testing and improving is difficult and uncommon. Since the different mechanical and electrical components are being developed and tested independently, overall system behavior can hardly be forecast. As a consequence, during the system assembly phase, unpredicted incompatibilities and system malfunctions can appear. In order to integrate the train subsystems into an overall system and allow for a better synchronization and proper system testing, the application of multi-domain model-ling and simulating is recommended. In this regard, the benefits brought by multi-domain applications will be discussed in this publication, using the example of a modern train. Thereafter, a case study of a pneumatic train brake application follows. Its results are exemplary being shown to demonstrate future perspectives. Models and simulation results of the brake and air supply components already turn out allowing for comparisons with the actual system. System start-up times of the simulation match actually measured times adequately.
Keywords: Multi-Body-Simulation; Modelica

Characterization and Optimization of Sn-Cu TLPS Interconnects for High Temperature Power Electronics through In-Situ-X-Ray Investigations - Syed Khaja, Aarief Hussain; Klemm, Alexander; Zerna, Thomas; Franke, Jörg (66th IEEE Electronic Components and Technology Conference, ECTC 2016, 2016)
The production of reliable power modules capable of achieving higher power densities and higher junction temperatures is limited by the present assembly and packaging methods, mostly in the areas of the die-Attach and the top level interconnections. The resultant bondline consists of intermetallic compounds with higher melting point than the used interlayer material, thus making this technique applicable to high temperature applications. This work gives an overview and compares the methodologies used to realize interconnections with respect to materials, processes and customization prospects. This work investigates the diffusion soldering process with In-situ X-Ray-Analysis and provides a deeper understanding of the process conditions and the materials used. The growth of intermetallic phases (IMPs) was analyzed as well. Based on the investigations and production results, a combination of vacuum and over-pressure profile is introduced for a reliable TLPS interconnection with acceptable void percentages.
Keywords: Diffusion soldering; In-situ; Intermetallic phase; Power electronics; Process optimization; TLPS; Voiding

Characterization and reliability of paste based thin-film Sn-Cu TLPS joints for high temperature power electronics - Syed Khaja, Aarief Hussain; Franke, Jörg (2015 International Exhibition and Conference for Power Electronics, Intelligent Motion, Renewable Energy and Energy Management, PCIM Europe 2015, 2015)
Electro-mobility plays an important role in addressing the fuel efficiency and emission requirements, as well as the market demands for low operational costs. Power electronics which is a key technology in electro-mobility motivates the present work. This paper gives an overview of the optimization of the present state-of-The-Art soldering technologies for diffusion soldering in power electronics, in particular for Transient Liquid Phase Soldering (TLPS) capable of producing die-Attach interconnections with remelt temperatures >400°C. The material characterization and reliability analysis of this thin-film Sn-Cu paste-based TLPS technology is discussed. For demonstration purposes, power modules had been constructed with solder pastes developed for TLPS process. High temperature shear tests up to 500°C and accelerated reliability tests have been performed to explain the possible microstructural defects and failure modes.
Keywords: Characterization; Die attach; Lead-free soldering; Power electronics; Transient liquid phase soldering

Characterization of alternative sinter materials for power electronics - Stenzel, David; Schwarzer, Christian; Schnepf, Michael; Chew, Ly May; Blank, Thomas; Franke, Jörg; Kaloudis, Michael (2019 22nd European Microelectronics and Packaging Conference and Exhibition, EMPC 2019, 2019)
Silver Sintering for die attach has gained increasing interest in past years. Compared to known interconnect materials such as Adhesives and Solder, the unique superior thermal and electrical properties of sintered silver joints enable power electronics to operate at greater reliability and at higher temperature. Copper, touted as the alternative, possess similar properties to silver and being the same material as metalized substrate can reduce CTE mis-match. Up till now copper sintering attracts great interest as an alternative optionfor die attach material. This study investigates the influence of using copper as the non-silver additives for formation of silver sintered layers as well as the effects on material properties of the sinteredjoints for die attach applications. The different sinter materials are evaluated by tensile strength, Young's modulus, die shear strength and electrical conductivity. Process-oriented test specimen were used to replicate the die attach layer formed duringpressure sintering. This contribution demonstrates that the mechanical and electrical properties of the sintered layer are affected by non-silver particles. It was found that the used filler materials can lead to a decrease of mechanical and electrical properties in comparison to the pure silver interconnection. It was also found, that the copper paste obtained a relatively strong bonding and confirms thefeasibility as an alternative die attach material.
CRIS-Team Scopus Importer:2020-02-21
Keywords: Copper sinter; Filler material; Silver sinter

Characterization of magnetic actuators by measuring of magnetic stray fields with GMR-sensors - Brela, Matthäus; Kassim, Najdet; Franke, Jörg (2013 3rd International Electric Drives Production Conference, EDPC 2013 - Proceedings, 2013)
Common defects in electromagnetic actuators due to manufacturing are heterogeneous magnetic properties of materials, cracks and defects in the flux guiding magnets and parasitic air gaps in and directly around the magnetic circuit. Considering the high cost pressure, test systems must adapt to the increasing complexity of the components and detect defects completely in-situ. For these requirements the novel and nondestructive measurement system is suitable to monitor and assure the quality of magnetic actuators within the manufacturing process. The measuring principle is based on the characterization of the magnetic circuit according to the magnetic stray fields that can be quantified by magnetoelectronic GMR-elements outside the circuit. GMR sensors are particularly suited due to their measurement range and their linearity. Their measurement range coincides with the magnetic stray fields which were demonstrated by magnetic field simulation of electromagnetic actuators. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electromagnetic actuators; GMR-sensor; magnetic stray fields; nondestructive measurement system

Characterizing the placement accuracy of a handling unit used for assembling 3D circuit carriers - Pfeffer, Michael; Franke, Jörg (Proceedings - 2013 IEEE International Symposium on Assembly and Manufacturing, ISAM 2013, 2013)
The assembly process of electronic components on three-dimensional circuit carriers increases the requirements on placement machines decisively. Decreased component packages and termination sizes require a precise placement process on 3D substrates with complex geometric structures. For characterizing the quality of this three-dimensional placement process, an evaluation methodology was developed. Therefore 3D test specimens were designed. The placement equipment, that has to be investigated, places components onto these specimens. Afterwards the component positions are analyzed by an optical coordinate measurement machine (CMM) and the placement error is calculated. This paper gives an overview of Molded Interconnect Technology (MID) and introduces the functionality of the investigated placement equipment, an automated multi axis handling unit for assembling 3D-MID. Focus is the presentation of the developed method for characterizing placement equipment used for 3D assembling of MID. Thedesign of the test specimens, the procedure of component placement and of measuring the component position areexplained. The results of characterizing the automated multi axis handling unit are shown. Influences and effects on the placement quality will be discussed. The developed method provides equipment manufacturers and users with a methodology to characterize, specify, document and verify the equipment's placement accuracy. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Molded Interconnect Device; Placement Accuracy; Surface Mounted Device

Choosing Identification Technologies for Implementation of Traceability in order to Increase Overall Equipment Effectiveness - Baier, Lukas; Hüttel, Franziska; Haintl, Alina; Schuderer, Peter; Franke, Jörg (Applied Mechanics and Materials, 2017)
Increasing the overall equipment effectiveness is a major task in order to further improve productive times and thereby increase energy efficiency. One main reason for ``energy waste'' besides inefficient machinery is spending energy on production or assembly of ultimately rejected parts. In order to decrease this kind of waste, traceability can be applied for identifying components and observing related parameters for detecting quality deviations in early states. Here, we show the required identification technologies in order to establish a traceability concept for assembly of discrete units. Evaluating existing techniques regarding their applicability depending on various constraints, is a major task when planning the traceability system. Therefore, we assessed different technologies generically to give hints for choosing techniques to consider. As known technologies often are accompanied by variable costs, additionally an efficient solution for low-value bulk goods is required. We describe some technical possibilities in order to enable implementation of a holistic traceability system. The given evaluation may be applied as basis for detailed investigations regarding technologies to use for identification of discrete objects in order to implement traceability. Through implementation of such measures significant scrap reduction and thereby an improvement of energy efficiency in various applications is possible. Nevertheless, further research may be taken on efficiently identifying low-value bulk goods.
Keywords: Bulk Goods; Identification of Small Low-Value Bulk Goods; Identification Technologies; Traceability

Closed-loop control of patient handling robots - Ziegler, Christian; Franke, Jörg (Studies in Computational Intelligence, 2013)
Patient handling robots are increasingly employed to enable a flexible positioning of the patient for diagnostic and therapeutic purposes. Due to the greatly differing robot loads because of varying patient weights especially serial kinematics are no longer able to keep up with the constantly increasing medical demands for positioning accuracy. In this chapter a low-cost measuring system for a permanent integration into the workspace of a patient handling robot is introduced which can measure the pose of a patient couch with high accuracy. This enables closed-loop control of the patient couch. In tests on a robot system an average positioning error of 0.12 mm was achieved for a diversity of medically relevant poses. © 2013 Springer-Verlag Berlin Heidelberg.
CRIS-Team Scopus Importer:2023-03-07

Cloud based Energy Management System Compatible with the Industry 4.0 Requirements - Javied, Tallal; Huprich, Sven; Franke, Jörg (IFAC PAPERSONLINE, 2019)
CRIS-Team WoS Importer:2019-11-22

Clustering of Image Data to Enhance Machine Learning Based Quality Control in THT Manufacturing - Thielen, Nils; Jiang, Zonghan; Schmidt, Konstantin; Seidel, Reinhardt; Voigt, Christian; Reinhardt, Andreas; Franke, Jörg (2021 IEEE 27TH INTERNATIONAL SYMPOSIUM FOR DESIGN AND TECHNOLOGY IN ELECTRONIC PACKAGING (SIITME 2021), 2021)
In this work, machine learning (ML) models are presented to identify false calls during quality control with automated optical inspection (AOI) in through hole technology (THT) manufacturing. While ML-based approaches with both, image data and numerical data, have already been investigated extensively in SMT manufacturing due to the higher market share, research for THT manufacturing does not have the same extend [1]. The presented models classify images into false calls and true defects, which were identified by the AOI as defects beforehand. Since the AOI uses different test routines to control pin, meniscus and foil of the different components and the board’s surface, multiple models for groups of images are developed to achieve better performance than a single one. To assign the images to the corresponding models, clustering of image data is done in two steps. First, the dataset is divided into subcategories based on the supplementary and descriptive data on the test routine. Second, the unsupervised machine learning algorithm k-means is used on images in each subgroup for further assignment to a dataset. A cumulative examination of the results of different convolutional neural networks (CNN) on the individual clusters leads to a relative improvement in false call detection of 6.8% while error slip can be reduced from 0.6% to 0% in an independent test data set, which is not used for model training.<br
CRIS-Team WoS Importer:2022-05-06
Keywords: Electronics Production; Through Hole Technology; Machine Learning; Automated Optical Inspection; Quality Control

CO2-Neutral Generation of Heat and Power in Smart Homes by Organic Rankine Cycle Powered Combined Heat and Power Micro Plants - Staub, Sebastian; Bauer, Jochen; Müller, Dominik; Franke, Jörg; Karl, Jürgen (Advanced Engineering Forum, 2016)

Combination of Flexographic and Aerosol Jet Printing for Integrated Polymer Optical Step Index Waveguides - Hoffmann, Gerd-Albert; Wolfer, Tim; Reitberger, Thomas; Lorenz, Lukas; Wolter, Klaus-Jürgen; Franke, Jörg; Overmeyer, Ludger (DGaO Proceedings 2016, 2016)
This paper describes the two stage fabrication of step index waveguides featuring parabolic cross sections with minimum widths down to 10 µm and aspect ratios of about 0.3. The waveguide itself is produced by aerosol jet printing on preconditioned areas with different surface energies which are generated on flexible substrates with an adapted flexographic printing mechanism.

Combining a collaborative robot and a lightweight Jamming-Gripper to realize an intuitively to use and flexible co-worker - Reitelshöfer, Sebastian; Ramer, Christina; Gräf, Daniel; Matern, Falko; Franke, Jörg (2014 IEEE/SICE International Symposium on System Integration, 2014)
By using collaborative robotic systems, new approaches like programming by demonstration can effectively be realized. As (re)programming of robots thereby gets fast and easy, such systems can facilitate the transition of industrial robots to flexible automation solutions suitable for small companies and small batch sizes. One reason that is preventing the usage of those robots on a broader scale is the fact that for nearly every different work piece a new gripping system has to be designed or at least mechanically adapted. The presented integration of a collaborative robot with a universal Jamming-Gripper broadens the spectrum of parts that can be handled by one robotic system without any mechanical modification.
Keywords: grippers; industrial manipulators; robot programming; collaborative robotic systems; flexible co-worker; gripping system; industrial robots; lightweight jamming-gripper; programming by demonstration; universal jamming-gripper; Educational institutions

Comparative Analysis of the Process Window of Aluminum and Copper Wire Bonding for Power Electronics Applications - Kästle, Christopher; Franke, Jörg (Proceeding of the 2014 International Conference on Electronics Packaging (ICEP), 2014)
Today's state-of-the-art top level interconnect technology in power modules is an aluminum wire wedge/wedge bond process. Being the bottleneck for realizing even higher switching frequencies and thus higher junction temperatures made possible by upcoming wide bandgap semiconductors, innovative packaging technologies such as copper wire wedge/wedge bonding are a key issue in pushing the technological frontier of power electronics even further. With its higher electrical and thermal conductivity as well as its lower coefficient of thermal expansion copper wire bonding bears the chance of a significant improvement in one of the most sensitive lifetime limiting areas of power modules. In contrast copper's higher young's modulus as well as a higher strain hardening require increased bond parameters resulting in new challenges for the bonding process. A smaller and more sensitive process window is expected to be the other side of the coin. This study aims to display the advantages and challenges of the aluminum and copper wire bonding process for power modules with special focus on a comparative analysis of their process windows. To obtain statistically significant conclusions all tests are performed in randomized rotatable central composite response surface design of experiment studies. A comparison of attainable shear forces as well as observed failure modes will be the bases to define criteria for acceptance that are applicable for the used wire bond material. This deep understanding of all process and process influencing parameters will be needed in order to set up and evaluate a reliable and optimized production process for power modules.
Keywords: DoE; heavy wire bonding; power electronics; process window; top level interconnections

Comparison analysis of the magnetic field and the magnetic force inside of an electromagnetic actuator with the use of an armature measuring sensor - Heyder, Andreas; Losch, T.; Meyer, Alexander Wilhelm; Abersfelder, Sandra; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Common errors in electromagnetic actuators must be reduced in order to meet the increasing requirements in quality and manufacturing costs. In-line magnetic process control is a promising method to avoid a great number of errors in early stages of production. This paper displays the meaningful correlation between the magnetic field and magnetic force characteristics of a proportional magnet. For this investigation, an armature measuring sensor is developed and implemented into a magnetic field test bench, which enables the realization of a so called smart factory.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electromagnetic actuator; in-line measurement; magnetic process control; three-dimensional magnetic field measurement

Comparison of Additive Balancing Processes for Rotors in the Context of High Speed Electric Traction Motors - Masuch, Michael; von Lindenfels, Johannes; Seefried, Johannes; Mayr, Andreas; Schneider, Michael; Weigelt, Michael; Kühl, Alexander; Franke, Jörg; Hemmer, Christian (2019 9th International Electric Drives Production Conference (EDPC), 2019)
In the ongoing development of electric traction motors with increasing volumetric power density, concepts are being developed for rotational speeds of more than 30,000 rpm. These motors require an especially high balancing quality. Due to the unavoidable material and production fluctuations, a tuning of the mass distribution regarding the rotation axis is necessary. This balancing can be achieved by subtractive or additive process alternatives. In this paper, an overview of current balancing approaches is given first. Based on this, the potentials and challenges of additive balancing methods, which directly apply material to the lamination stack, are explained. In this context, two joining processes, namely ultrasonic welding and laser beam welding, are examined in more detail on the basis of practical experiments. In particular, influences on the quality of the lamination stack are considered.<br
Keywords: balancing; rotor; electric motor production; manufacturing; NVH; laser beam welding; ultrasonic welding

Comprehensive correlation of inline inspection data for the evaluation of defects in heterogeneous electronic assemblies - Härter, Stefan; Klinger, Tobias; Franke, Jörg; Beer, Detlef (2016 Pan Pacific Microelectronics Symposium, Pan Pacific 2016, 2016)
With increasing miniaturization and complex features of modern electronic products, there is a growing demand for highly integrated printed circuit boards. Small passive parts such as the component size 01005 (0402 metric) provide smaller assemblies for mobile consumer products, sensor devices as well as medical applications. Based on literature, the solder paste printing process is considered to be the most critical process step in the Surface Mount Technology. Solder Paste Inspection (SPI) offers opportunities for monitoring this process step. Furthermore closed loop applications using SPI data are highly offered in the industry, e.g. for the correction of a measured print offset or the specific execution of an internal understencil cleaning process of the printer. The introduction of micro passive parts does however have its drawbacks especially in an assembly with heterogeneous components. On the process side, the paste printing with a wide spectrum of components often induces critical values for the aspect ratio on the stencils used. Furthermore, the micro passive parts place high demands on the inspection processes by SPI and Automatic Optical Inspection (AOI) and Automatic X-ray Inspection (AXI). Beside the machine capability for high quality inspection the correlation of all inspection data and the cause of defects is still not fully understood and offers enormous potential. This study is a holistic approach for evaluation of inspection data of the process steps for acquisition of knowledge about the development and avoidance of real defects. For the investigations, a 4-layer-PCB (FR4) is developed with dimensions of 180 mm by 110 mm in size and a thickness of 1.0 mm. Over 20 different kinds of packages (e.g. BGA, QFN, SOT, etc.) and passives of the component size 0603 and 01005 provide a mixed assembly with about 1,250 components on each PCB. Design of experiments is used for the study for statistical analyses of a wide range of influencing factors. In the test series variations of the metallization of the PCB (NiAu and chem. Sn), different suppliers for the solder material (lead-free SAC305), the type of the solder paste (type 4 and type 5), the stencil thickness (80 μm and 100 μm) and two different reflow profiles are considered. The use of SPI and AOI/AXI machines from the same supplier enables the correlation of the huge amount of measured inspection and quality data. By tracking all manufacturing data the failure development for the complete process chain can be analyzed. The inspection results performed by AOI and AXI machines show several defects on the PCBs like tombstones of 01005 and 0603 components as well as solder bridges on 'QFN32' packages. The related SPI data reveal possible causes of these failures and can be explained by PCB design issues or specific process control. In addition, 'self-healing effects' of critical SPI results were observed, e.g. all detected bridges for 'MS0P10' devices in the SPI show no real defects in the AOI. By correlation of all SPI and AOI/AXI results for each type of component the influence of the solder paste printing on the final electronic assembly is observed. Also strategies for low false call rates in the SPI and limits for the printing results of 01005 components are discussed. The missing correlation of inspection data and the final results within the evaluation shows the complexity of the numerous influencing factors in the production of miniaturized electronic devices.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Closed Loop; Inspection; SMT 01005

Computer-Aided Design and Simulation of Spatial Opto-Mechatronic Interconnect Devices - Zeitler, Jochen Tobias; Reichle, Andreas; Franke, Jörg; Loosen, Florian; Backhaus, Carsten; Lindlein, Norbert (26th CIRP Design Conference, 2016, 2016)
Optical technologies become increasingly important in modern sensor and communication applications. Nevertheless, manufacturing and design methods in the field of spatial opto-electronics have not been investigated intensively yet. A new approach is to print polymer waveguides on spatial carriers to use the full design freedom of opto-mechatronic assemblies. Up to now, no specific design tools and validation methods are available. The article describes possible technology-specific methods for designing spatial opto-mechatronic applications with the focus on computer-aided design (CAD) and raytracing simulation of spatial waveguides.
Keywords: computer-aided design (CAD); design method; optical communication; opto-electronics; simulation

Concept for an integrated product and process development of electric drives using a knowledge-based system - Mayr, Andreas; Meyer, Alexander Wilhelm; Gönnheimer, Philipp; Gramlich, Jonas; Reiser, Maximilian; Franke, Jörg (2017 7th International Electric Drives Production Conference (EDPC), 2017)
The development and production of electric drives as mechatronic products involve several engineering domains. With increasing complexity of the individual parts, frequently shifting customer requirements and ever shorter development cycles, integrated approaches are continuing to grow in importance. In this context, an interdisciplinary design methodology supports in mastering complexity and in creating independence from project managers' varying competencies. There are already more general approaches for mechatronic products and approaches covering the entire electric car. However, for electric drives, whether used in cars or industrial automation, no comprehensive knowledge-based approach considering product as well as production-related aspects has yet been established. Due to the interdisciplinary expertise needed for an integrated product and process development, it is necessary to manage the extensive domain knowledge by means of a sophisticated information system. Hence, this paper will provide a concept for a knowledge-based system supporting the product and process development of electric drives. As part of a basic consideration the presented approach focuses on the key component of such a system - the knowledge base. Therefore, suitable knowledge representation methods are evaluated, followed by the selection of the most appropriate one to fulfil the underlying requirements. Thereafter, the type of database for the system's implementation is chosen. Finally, the adequately modeled knowledge base is transferred to the database in an exemplary manner.<br
Keywords: integrated product and process development; design methodology; knowledge management; knowledge-based system; semantic network; graph database; electric drives

Concept for Automated Fuse and Relay Assembly in the Field of Cable Harness Manufacturing - Heisler, Paul; Sand, Christian; Hefner, Florian; Süß-Wolf, Robert; Franke, Jörg (RWTH Aachen 2017 – 7. WGP-Jahreskongress, 2017)

Concept for a virtual process data linkage of assembly stations and a dynamic envelope curve for process monitoring - Sand, Christian; Meiners, Moritz; Daberkow, Jonas; Franke, Jörg (2016 6th International Electric Drives Production Conference, EDPC 2016 - Proceedings, 2016)
Industrial manufacturing and assembly aim to realize a wide range of product variance at high quality standards. [7] The fabrication processes are commonly organized as workshop production or chained production systems, besides standalone machines. [3][4] A lot of process data is generated by every single machine, yet it is hardly used for process optimization. Depending on the manufacturing IT, process data of series production is stored within databases optimized for traceability, whereas standalone machines and machines within workshop production are usually not connected to a common database. The required process data is either stored on the assembly machine itself or inside a local database. [9] The identification of interdependences of each single assembly process and the quality of the finished good is necessary for advanced optimization. Due to the decentralized process data storage, data mining analysis is taking a huge amount of time to find and prepare the process and quality data, especially in workshop production. To enable process monitoring and holistic optimization based on data mining methods in workshop production, a methodology is required to extract, transform and store process data like pressing curves and quality data. Therefore, this paper provides a concept for a virtual process data linkage of assembly stations to enable data mining inside workshop production, which is also able to cope with chained production systems and standalone machines. For further analysis of interdependencies of assembly presses, a dynamic envelope curve is developed for advanced monitoring and optimization as novel methodology.
CRIS-Team Scopus Importer:2023-03-07
Keywords: assembly machines; data mining; envelope curve; process optimization

Concept for a virtual process data linkage of assembly stations and a dynamic envelope curve for process monitoring - Sand, Christian; Meiners, Moritz; Daberkow, Jonas; Franke, Jörg (Electric Drives Production Conference (EDPC), 2016 6th International, 2016)

Concept for Magnet Intra Logistics and Assembly Supporting the Improvement of Running Characteristics of Permanent Magnet Synchronous Motors - Meyer, Alexander Wilhelm; Heyder, Andreas; Kühl, Alexander; Sand, Christian; Gehb, Hermann; Abersfelder, Sandra; Franke, Jörg; Holzhey, Rocco; Buettner, Ulrich; Wangemann, Sebastian (Procedia CIRP, 2016)
Current scientific studies prove the dependency of the running characteristics of permanent magnet synchronous motors on variations of the physical properties of permanent magnets and manufacturing errors. Currently, this fact is not considered in most process chains for magnet and rotor assembly. Thus, insufficient rotor quality can only be detected during the end-of-line test, causing rejects of whole motors. As a solution for these drawbacks, a computerized magnet intra-logistics storage and assembly concept is presented, using sophisticated magnet measurement technologies. This concept allows for the traceability of single magnets and enables to compensate variations of the magnetic properties by selective magnet assembly.
CRIS-Team Scopus Importer:2023-03-07
Keywords: magnet assembly; magnetic tolerancing; PMSM; tolerancing; traction drives

Concept of a Machine Learning supported Cross-Machine Control Loop in the Ramp-Up of Large Series Manufacturing - Meiners, Moritz; Franke, Jörg (2020 IEEE 11th International Conference on Mechanical and Intelligent Manufacturing Technologies, 2020)

Concepts for the design and optimization process of printed polymer-based optical waveguides (scattering processes) - Loosen, Florian; Backhaus, Carsten; Lindlein, Norbert; Zeitler, Jochen Tobias; Franke, Jörg (Proceeding, 4th doctoral students conference on optics (DoKDoK), 2015)

Conceptual design of an intelligent ultrasonic crimping process using machine learning algorithms - Weigelt, Michael; Mayr, Andreas; Seefried, Johannes; Heisler, Paul; Franke, Jörg (28th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2018), 2018)

Conditioning of Surface Energy and Spray Application of Optical Waveguides for Integrated Intelligent Systems - Hoffmann, Gerd-Albert; Reitberger, Thomas; Franke, Jörg; Overmeyer, Ludger (2016)
Networks of optical waveguides allow for data transmission and sensing applications. Therefore, this technology is a key element for the integration of intelligent systems and structural health monitoring. Optical waveguides are the essential backbone to connect these structures. The flexible and high-resolution manufacturing of waveguides, also on three-dimensional substrates, is accomplished by a combination of two printing processes. In the first step, flexible substrates are conditioned by a printing technology with an adapted flexographic printing mechanism. To produce the optical waveguide itself, the Aerosol-Jet-Printing process of liquid polymer or varnish is used on pre-conditioned areas with hydrophobic or hydrophilic behaviour. Waveguides fabricated by this two-stage process reach parabolic cross sections with a minimum width down to 10 µm. This paper shows the mechanism for the use of the processes and latest results concerning the choice of materials, which allow the operability for this kind of manufacturing. We show the adaption of the local surface energy by the printing technology to achieve a self-configuration of UV varnishes for highresolution waveguides.
Keywords: Flexographic Printing; Aerosol Jet; Conditioning; Optical Waveguide; Surface Energy

Configuration based process and knowledge management by structuring the software landscape of global operating industrial enterprises with microservices - Schäffer, Eike; Leibinger, Hannes; Stamm, Axel; Brossog, Matthias; Franke, Jörg (Procedia Manufacturing, 2018)
An increasing amount of enterprises is currently facing the topic “knowledge and process management” to be more efficient and to be able to introduce concepts of Industry 4.0. The challenge for these companies, which are mostly not Original Equipment Manufacturers (OEM), but medium to large component suppliers, is that they do not have resources and expertise to establish large corporate departments that will be responsible for standardization. With our concept based on Microservices (MS), we deliver a smart and straightforward system approach that can be implemented, dependent on the available resources, with little external IT support. There is no need of an organizational restructuring that goes along with major invests. Existing stand-alone tools are transferred into a common structured syste
Keywords: Configuration; knowledge management; standardisation; Microservice

Configurators as the basis for the transfer of knowledge and standardized communication in the context of robotics - Schäffer, Eike; Bartelt, Matthias; Pownuk, Tobias; Schulz, Jan-Peter; Kuhlenkötter, Bernd; Franke, Jörg (Procedia CIRP, 2018)
Complex robot systems and intelligent automation concepts play a key role in manufacturing companies. Due to the required high level of expertise in such systems, many robot automation solutions do not achieve a good economical cost-benefit ratio. In order to meet these challenges, intuitive engineering platforms are urgently needed. In this paper, we present the evolution of such a platform, which we are building in a modular way. By using a configuration module, best-practice automation solutions are modified in order to meet specific requirements. With this, employees without special knowledge of robotics can achieve optimized automation solutions quickly.<br
Keywords: Robot-based Production; SystemsManagemet of Knowledge; Configurator; Onion-View Model; AutomationML

Conformable Electronics: Thermoforming and Injection Molding of Electronic Components - Schirmer, Julian; Reichenberger, Marcus; Neermann, Simone; Franke, Jörg (Proceedings of the International Spring Seminar on Electronics Technology, 2021)
In this paper the stress on electronic components for Conformable Electronic applications is evaluated. During High-Pressure-Forming (HPF) and subsequent overmolding (OM) these components have to withstand high amounts of stress. Globtops are used to protect 0402 as well as 0603-sized components mounted on different polymer substrates. The components are placed in different areas of deformation (for HPF) and melt velocities (for OM). The components are afterwards examined by means of electrical resistance measurements and shear force measurements as well as micro-sections. For conductive adhesive, the globtop material positively influenced the resistance change after deformation, soldered assemblies showcased good formability up to 20 %. The shear force drop caused by higher deformations could be mitigated using globtop materials. Soldered components were able to withstand OM when globtops were used. Here, smaller components seem to take less damage from the impacting melt. Components should be placed in areas where the melt has cooled down to prevent damages.
CRIS-Team Scopus Importer:2021-09-10

Continuous aerosol-jet-printing of silicone layers for dielectric elastomer actuators - Reitelshöfer, Sebastian; Landgraf, Maximilian; Yoo, In Seong; Franke, Jörg (5th International Conference on Electromechanically Active Polymer (EAP) & Artificial Muscles (EuroEAP), 2015)

Continuous Improvement of the Screen printing Process of Magnetic Sheets for Electric Machines by Statistical Design of Experiment - Schmidt, Alexander; Wieprecht, Nico; Thamm, Julian; Kühl, Alexander; Franke, Jörg (Lecture Notes in Mechanical Engineering, 2023)
Electric machines are an essential element to the electrification of industry and mobility for achieving a sustainable economy. Particularly important are the resource-efficient production of stator and rotor sheet packages and the reduction of iron losses during operation. The screen printing technology enables the production of very thin magnetic sheet laminations in near net shape geometry and thereby minimization of material waste in production. Simultaneously the efficiency of electric motors in use will be increased by reduced eddy current and hysteresis losses due to decreasing sheet thickness and avoided mechanical stress in the manufacturing process. In addition, screen printing enables multi-material components and variable alloy compositions. This paper presents the requirements of the screen printing process for magnetic sheets and identifies the relevant influencing factors and printing parameters to achieve the product specifications in multiple iterations and using universal statistical design of experiments methods. The target parameters investigated are cycle-time, green part weight, roundness, and layer thicknes
Keywords: Additive Manufacturing; Electric Motor; Magnetic Sheets; New Materials; Resource-efficient Production

Continuous rotational cutting of laminations for electric drives: Cutting process and tool setups for rotational cutting of laminations - Hubert, Markus; Franke, Jörg; Hackert, Jürgen (2014 4th International Electric Drives Production Conference, EDPC 2014, 2014)
Rotational cutting of stator and rotor laminations has the potential to bridge the gap between laser cutting in the production of prototypes and high-speed punching in mass production. Furthermore with this process, a technological answer to the production of ever thinner stator and rotor laminations can be found in which high-speed punching is reaching its technical limits. In this paper the process for rotational cutting of thin electric sheets is described in general and various concepts for tooling setups are presented. In addition it is described how the deviating process chain in the manufacture of cutting cylinders leads to a change in the product geometry.
Keywords: Electric Sheet Processing; Rotational cutting; Tooling

Contribution of Additive Manufacturing of Rare Earth Material to the Increase in Performance and Resource Efficiency of Permanent Magnets - Urban, Nikolaus; Meyer, Alexander Wilhelm; Keller, Vitalij; Franke, Jörg (AMM (Applied Mechanics and Materials), 2018)
Keywords: Additive Manufacturing; Laser Beam Melting; LBM; Magnet; SLM

Contribution to the Reduction of Annealing Processes in the Manufacturing of Valve Solenoids by Using Inline Measuring Technology in the Caulking Process - Freiherr von Lindenfels, Johannes; Heyder, Andreas; Funk, Stefan; Pigler, Stefan; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production IV, 2018)
Electromagnetic actors (solenoids) are used in automotive and automation technology as valve actors for pneumatics and hydraulics or as actuating and pressure solenoids. During assembly there are often press-in and caulking processes used. A central quality aspect of the final control elements is the adherence to defined actuating force ranges in order to ensure the switching process and at the same time to keep wear within limits. These defined force ranges can currently only be maintained by additional heat treatment of the parts. The hysteresis of the assembled unit can be influenced by the caulking. The objective of this paper is to propose the potential reduction of annealing processes by revealing the interdependencies between the magnetic interactions of the individual components and the assembly process parameters. In addition, errors in the caulking process are detected and prevented at an early stage. A magnetic characterization of the soft magnetic components and assemblies before and during their assembly is proposed. Furthermore, the integration of the measurement data into a process control system is intended. The precondition is the development and construction of measuring equipment and systems that can be used to assess the magnetic properties at an early stage of assembly. The assembly can then be adjusted in order to compensate batch fluctuations. As a consequence new materials can be used to eliminate complex annealing processes prior to assembly. <br
Keywords: Caulking; Hall Sensor; Inline Measuring Technology; Solenoids

Control of a Hybrid Energy Storage System for a Hybrid Compensation System - Böhm, Ralf; Steglich, Michael; Rehtanz, Christian; Paulsburg, Martin; Datsevich, Sergey; Brunner, Benjamin; Franke, Jörg (Chemical Engineering & Technology, 2019)
The combination of two or more different energy storage technologies in a hybrid energy storage system appears to be advantageous if the combination of technologies fulfils the storage purpose better than a single storage technology. Herein, requirements regarding the performance of the storage system are determined for a hybrid compensation system for provision of system services in medium-voltage grids. In hybrid storage systems, a common control system ensures that the present storage technologies are utilized in such a way that total storage efficiency is highest and that usability of the application is maximized. The control system of a hybrid storage system consisting of a redox flow battery and high-speed flywheel storage is introduced and evaluated.
CRIS-Team Scopus Importer:2019-07-09
Keywords: Energy management; Hybrid storage system; Power management

Control of a hybrid storage system (HSS) comprising a RedOx-Flow Battery and a High Speed Flywheel for a hybrid compensation system - Böhm, Ralf; Weindl, Christian; Franke, Jörg (2018 IEEE PES INNOVATIVE SMART GRID TECHNOLOGIES CONFERENCE EUROPE (ISGT-EUROPE), 2018)
CRIS-Team WoS Importer:2019-03-01

Control strategy for an industrial process monitoring robot - Zimber, Fabian; Horváth, Csongor Márk; Thomessen, Trygve; Franke, Jörg (SII 2016 - 2016 IEEE/SICE International Symposium on System Integration, 2017)
The installation of industrial robot systems requires considerable human effort both related to the mechanical and electromechanical setup. However, the task of programming a robot is of particular importance to satisfy given process requirements. Typically, only 20% of the entire programming time is needed to define the path and logics while the remaining 80% is related to process optimization. This causes considerable costs due to the need for human presence. With a remote assistance system and a process monitoring robot, expert assistance could be decoupled from the physical presence. An important challenge is to solve the tracking between the monitoring robot and the robot performing the process. In this paper we propose a controllable sensor system for enhanced process monitoring. The system is decoupled from the process tool and can therefore be controlled independently. It provides the machine operator with adaptive process information and enhances the capabilities to qualify complex processes. We apply the concept to an autonomous sensor robot monitoring an industrial robot system for heavy, multipass TIG welding of voluminous workpieces.
CRIS-Team Scopus Importer:2023-03-07

Cooperative Processing with Multi-Robot Systems - Wagner, Maximilian; Heß, Peter; Reitelshöfer, Sebastian; Franke, Jörg (IEEE/ASME International Conference on Advanced Intelligent Mechatronics, AIM, 2017)
Multi-robot systems are increasingly utilized for cooperative industrial robot applications. In the scope of this work, a novel approach for the division of robot applications between multiple robots by handling the tool and the workpiece at the same time is presented. The approach has been tested successfully with a robot setup with two industrial robot arms. It is shown that the processing time can be reduced and the reachability can be improved by the developed approach. In order to compensate complex programming of the cooperative tasks, an automatic programming is also realized. Thus, the programming time can be significantly reduced.
CRIS-Team Scopus Importer:2023-03-07

Copper circuit traces by laser cladding with powder injection for additive manufactured mechatronic devices - Müller, Martin; Hentschel, Oliver; Schmidt, Michael; Franke, Jörg (Proceedings of the 2016 IEEE 18th Electronics Packaging Technology Conference, EPTC 2016, 2017)
Laser cladding allows for a fast, flexible and direct plotting of electric conductive structures on polymer based substrates. The surface of the substrate is selectively melted by a focused laser beam. Simultaneously, a metal powder is lead through a powder nozzle. This nozzle is oriented laterally or coaxially to the laser beam. As a result, a molten bath of substrate and powder material is created. After cooling and solidification a welding bead on the substrate surface is formed. With this generation of circuit traces mechatronic devices can be built up, especially for high current power electronic applications. In this paper copper circuit traces on polymere substrates, produced by laser cladding with powder injection are characterized for their optical, electrical and mechanical properties by measuring resistance, adhesive strengths and current-carrying capacity including the effects of simulated environmental influences.
CRIS-Team Scopus Importer:2022-06-05

Correlation Analysis of Factors Influencing the Motion Planning Accuracy of Articulated Robots - Kedilioglu, Oguz; Nikol, Markus; Walter, Jonas; Franke, Jörg (2023 9th International Conference on Automation, Robotics and Applications (ICARA), 2023)
The motion planning accuracy of articulated robots can be increased by augmenting them with an objective function. Parameters that influence the absolute accuracy of 6-axis articulated robots can be integrated into such objective functions. However, it is still unclear how to prioritize the various influencing factors so that they can be utilized together instead of separately. Here, it is shown how to rate these factors by analyzing and comparing their impact on the accuracy of the robot. The factors manipulability, smoothness, gear backlash caused by direction change of axis rotation, joint space distance and robot layout are studied in this regard. The evaluation with a 6DoF laser tracker reveals that manipulability and smoothness have the biggest impact. With these results it is possible to combine multiple factors into a comprehensive function and achieve a higher accuracy without the necessity of applying any hardware upgrades.<br

Correlation between Residual Stress, Building Angle and Illumination Parameters of Additive Manufactured FeSi6.5 and Mechanical and Magnetic Properties - Urban, Nikolaus; Detrois, Jannik; Franke, Jörg (2020 10TH INTERNATIONAL ELECTRIC DRIVES PRODUCTION CONFERENCE (EDPC), 2020)
CRIS-Team WoS Importer:2021-07-23

Cost-efficient, true silicone printer with variable material spectrum for individualized medical applications - Martin, Sina; Gugel, Lukas; Martin, Thomas; Preis, Alexander; Reitelshöfer, Sebastian; Franke, Jörg (Procedia CIRP, 2021)
Due to their beneficial material properties, silicones have become increasingly important in the healthcare sector. However, common manufacturing techniques like injection molding are limited. Hence, silicones have become more interesting for additive manufacturing, as it is possible to freely shape individualized products in small quantities. We present a syringe printer architecture for personalized manufacturing of medical products that allows a variable mixing ratio for RTV-2 crosslinking silicones and precise dosing. Compared to other printing methods, various commercially available one or two-component silicones with variable part viscosities can be printed in a broad range from 10-3Pas up to 10³ Pas.
Keywords: Additive manufacturing; individualized healthcare; silicone printing; medical grade silicones

Cost engineering in practice – Empirical investigation of cost calculation tools - Lutz, Manuel; Bodendorf, Frank; Stepanek, Niklas; Franke, Jörg (10th CIRP Sponsored Conference on Digital Enterprise Technologies (DET 2020) – Digital Technologies as Enablers of Industrial Competitiveness and Sustainability, 2021)
Cost calculation systems are increasingly being implemented in original equipment manufacturing as well as in supplying companies. However, the benefits of these systems in terms of cost and time reduction have not yet been scientifically investigated. In an empirical study, different software solutions for product cost calculation in practice are analyzed and potential benefits identified. The results show that software packages based on CAD, ERP or PLM (1) combined with stand-alone calculation tools (2) are a promising way for cost estimation in industrial product development.
Keywords: Cost; Simulation; Management

Coupled Thermal and Fluid Mechanical Modeling of a High Speed Motor Spindle - Koch, Lukas; Müller, Julian; Michos, Gordana; Paulus, Johannes; Hubert, Markus; Franke, Jörg (Applied Mechanics and Materials, 2017)
The objective of this survey is to evolve a better understanding of the complex thermal interactions inside a motor spindle. Therefore, the thermal behavior is investigated based on a simulation model and experiments. In contrast to existing simulation models, which either performed a complex thermal examination or an elaborate flow-mechanical analysis, a thermal (Finite Element Method) and fluid mechanical (Computational Fluid Dynamics) coupled simulation model was developed. Based on a comparative analysis, the usability of the currently available boundary conditions is scrutinized.

Crack detection in PM-rotors using magnetic field measurement and data processing - Abersfelder, Sandra; Meyer, Alexander Wilhelm; Heyder, Andreas; Herzog, Moritz; Franke, Jörg; Brela, Matthaeus (2017 7th International Electric Drives Production Conference, EDPC 2017 - Proceedings, 2018)
Electric drives efficiency is determined by the mechanical and magnetic properties of the functional elements stator and rotor. Focus element for this investigation is the rotor including its permanent magnets. Due to several manufacturing influences the properties of those magnets vary considerably. Magnet failures that can occur during manufacture are cracks, blowholes or inclusions, which can lead to commutation problems or to increased noise [1]. Crack propagation is a long-lasting process and cause unintentional failure in field. Currently no automated quality inspection of micro cracks is available in electric drive production. Consequently, the challenge is to develop reliable and safe process concept, to separate bad from good rotors based on magnetic field measurements in order to detect failures at the internal or external assembled magnets. For this purpose, a data analyzing method was developed to identify and characterize micro cracks in already assembled permanent magnets.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Actuators and System Integration; Crack Detection; Data Processing; Fault Detection; Magnetic Field Measurement; Permanent Magnet; Sensors

Creating realistic human model motion by hybrid motion capturing interfaced with the digital environment - Bönig, Jochen; Perret, Jerome; Fischer, Christian; Weckend, Holger; Döbereiner, Florian; Franke, Jörg (FAIM 2014 - Proceedings of the 24th International Conference on Flexible Automation and Intelligent Manufacturing: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation, 2014)
A key challenge in production engineering projects is to achieve significant time and cost savings through early validation of manual assembly operations. Nevertheless, the use of digital human models for dynamic analyses is not very prevalent because of the high modeling complexity in the digital environment: with existing simulation tools, the worker's motions are either unrealistic or too time-consuming to program. Hence, further research is needed for developing a time-saving and realistic human motion simulation. In this article, we present an experimental setup for the early validation of manufacturing tasks through interactive simulation. We use a new hybrid motion-capture system interfaced with the digital environment, which facilitates the generation of realistic human model motion in real time. The software platform used is DELMIA V5. The article describes the relationship between optical and inertial tracking, and how the drift of the inertial sensors can be compensated by using a kinematic chain with a human model. Sequences of postures can be saved, both for the human model and tools, and later replayed synchronously. Finally, we detail the use of our setup in a real-world scenario within automotive manufacturing. This article acts as a practical contribution to simulation-based Manufacturing Ergonomics and Human Factors, illustrating the effectiveness of state-of-the-art technology for viable cost and time savings.
CRIS-Team Scopus Importer:2023-03-07

Crossbench and Evaluation of Additive Manufacturing Processes in Strategy of Sustainable and Energy Efficient Production - Kreitlein, Sven; Urban, Nikolaus; Gerter, Viktor; Franke, Jörg (Applied Mechanics and Materials, 2017)

Cross-Process Quality Analysis of X-ray Tubes for Medical Applications Using Machine Learning Techniques - Selmaier, Andreas; Robitzch, Phillipe; Mayr, Andreas; Fürst, Jens; Franke, Jörg (Production at the leading edge of technology, 2019)
X-rays have a large range of medical applications and play an important role in imaging diagnostics. However, the ionized radiation that the patient is exposed to during its application is harmful. In order to keep the radiation exposure as low as possible and at the same time improve image quality, the development of X-ray tubes is being pushed to physical limits. These increased requirements create new challenges not only for product development, but also for the production of X-ray tubes. In addition to the chemical composition of the raw material, the manufacturing processes play a significant role in the quality and service life of the products. In order to obtain updated cause and effect relations and knowledge about the product from the quantity of influencing factors, a cross-process analysis of the manufacturing data is necessary. While classical statistical methods reach their limits in this task, machine learning (ML) algorithms seem promising in the analysis of high-dimensional data. However, according to today's state of the art, such analyses are accompanied by a considerable amount of pre-processing and data cleansing. This paper presents an approach with which the cross-process analysis of product quality can be realized in an efficient manner by creating a standardized procedure. The validation of the approach is based on a prototypical implementation for two product lines.<br
Keywords: Cross-Process Analysis; CRISP-DM; Machine Learning; RAMI 4.0; X-ray Tube Production

Current Distribution Monitoring in Capacitor Discharge Welding - Meiners, Moritz; Reichenstein, Tobias; Franke, Jörg; Hauenstein, Rainer (2020)
The capacitor discharge welding (CDW) is a resistance welding process that excels through brief process times, low thermal stress, and good automation potential. Nevertheless, potential industrial users hesitate to use the CDW process, owing mainly to the unavailability of automated process control to ensure cost-efficient production and high product quality. For quality assurance, representative values or process curves of the most critical process parameters such as capacitor energy, contact force, electric current, and sink-in depth are monitored. The lack of full significance of this monitoring is indicated by the regular destructive testing of random samples through load tests and cross-section analysis. The essential aspect of the process quality is heat development in the welding zone. The current distribution, as one crucial parameter influencing heat development, is missing. Therefore, this paper presents an in-situ qualitative, indirect current distribution measurement system. The new measurement supplements the process monitoring and analysis, and thus, gain new process knowledge. With better process monitoring and thus understanding, new application areas can be developed for CDW.<br
Keywords: capacitor discharge welding; current distribution monitoring; sensor system; resistance welding; hall effect sensor

Customizable Capacitive Sensor System Using Printed Electronics on Window Glass - Fröhlich, Jan; Gräf, Daniel; Franke, Jörg; Hörber, Johannes; Hedges, Martin (2020 Pan Pacific Microelectronics Symposium, 2020)
Printed electronics offer new possibilities in the design of footprints and integrated mechatronic systems. Fast and uncomplicated customization and cost-efficient fabrication are further benefits of this technology. In combination with other production processes like pick-and-place systems or fused filament fabrication (FFF), functional applications like communication or sensing devices can be produced in a very flexible way. The authors demonstrate how to produce a capacitive sensor system on three millimeter window glass by combining the piezo-jet technology and a pick-and-place system within a single five-axis CNC machine. The piezo-jet system is used to produce the circuitry by printing silver micro paste onto the glass plate. The process is maskless, works with a standoff-distance between one and ten millimeters and can process inks and pastes with a viscosity from 50 mPas to 200,000 mPas. The pick-and-place system puts all necessary surface mounted devices (SMD) directly onto the liquid paste which contains adhesives. The only process that takes place outside the machine is the sintering. However, by integrating an ultra violet (UV) or near infrared (NIR) curing system this process step could also be carried out within the machine. After the sintering the system is fully functional and does not require any further post-processing. The system consists of a micro-controller, two capacitive proximity detection ICs, resistors and capacitors. The digital outputs of the sensors could be used to control any given application, for reasons of illustration the functionality of the system is shown by an additionally mounted LED-strip. The system is easy to design and quick to adapt since the electronic layout is based on the standard layout of the IC-provider and the used software uncomplicated and open-source. Due to the placement at the back of the glass the system is perfectly protected against mechanical and chemical influences. It detects all kind of materials so the sensors can be triggered while wearing gloves or by people with a hand prosthesis. Moreover, the sensitivity can be easily adjusted over the software of the microcontroller which makes the application easy adaptable to several conditions. By recognizing different touch patterns, different operating modes can be performed. Currently the sensor system works as a touch switch, but it could also be adapted to realize a low-cost distance sensor. The flexibility of the used five axis system in combination with the high standoff-distance of the piezo-jet print head offers the possibility to print such systems on a wide spectrum of three-dimensional bodies. Even printing around or into corners is possible. With this method existing components can be functionalized electronically without having to redesign them. The produced demonstrator shows the possibility to extend a component by operating elements, but the capabilities go much further. Existing components can not only be extended by numerous sensor functions, communication elements such as Bluetooth or W-Lan antennas can also be realized in this way.
CRIS-Team Scopus Importer:2020-05-15
Keywords: capacitive; manufacturing process; printed electronics; sensor system

Cutting-edge engineering - An innovative approach to better support the engineering and the life cycle of automated production systems - Merhof, Jochen; Franke, Jörg (Advanced Materials Research, 2013)
This article describes how a future engineering of production systems could look like and what the benefits would be. The presented concept is requirement-based and uses a role-concept and aggregation to deal with the increasing complexity of mechatronic systems. The aim is to counteract the increasing complexity of the systems. For this purpose, strategies must be identified and implemented to achieve this. Finally, an approach for implementing this concept is described. © (2013) Trans Tech Publications, Switzerland.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Data model; Engineering; Semantic description of automated production systems

Cyber-physical compressed air systems enable flexible generation of compressed air adapted to demand of production - Böhm, Ralf; Weyrich, Sven; Franke, Jörg (7. WGP-Jahreskongress, 2017)
Industrial compressed air systems (CAS) embrace significant potential for saving both energy and cost due to their share of 7 % of the total industrial electricity consumption in Germany. In electric energy systems based on renewable generation plants supply and demand often do not occur in the same period of time. Consequently demand side management (DSM) is gaining importance whereby decentralized automation offers opportunities in industrial environments. Supply systems on industrial plants supply manufacturing equipment with compressed air, nitrogen and other technical gases, which partly can be obtained from air by deposition processes. Those systems consist of air compressors, gas separators, reservoirs and lines. With suitable dimensioning and by equipping with automation technology those systems can be used for demand side management purpose. In addition to basic operating parameters like current air pressure and status, those systems can process further information and create, for example, profiles on compressed air consumption over time. By enriching those profiles with data on pressure, volumes, system restrictions and current production requirements, the system control can identify the available potential for demand side management. Evaluation of operational strategies has to optimize conflicting objectives within the triangular relationship of storage design, control of the production according to price prospects and influencing or predicting the use of compressed air and technical gases obtained from air. For economical advantageousness of cyber- physical supply systems time flexible procurement prices for electric energy are required, enabling the utilization of use low prices in times of high supply. Costly production downtime due to inactive supply, caused by high electricity price has to be avoided mandatorily. Within the article, a conceptual approach for connection of CAS to production planning systems (PPS) will be presented and challenges as connecting demand forecasting and compressor control will be outlined.
Keywords: Energy efficiency; Neural network; Compressed air systems; Operating strategies; Demand forecast; Machine learning.

Cyber-Physical Electronics Production - Kästle, Christopher; Fleischmann, Hans; Scholz, Michael; Härter, Stefan; Franke, Jörg (Industrial Internet of Things, 2017)
Cyber-physical manufacturing networks bear the chance to change the face of tomorrow’s electronic and mechatronic products as well as their production systems. The ability to integrate miniaturized sensors and printed communication technologies into materials, machines, and products leads to autonomous cyber-physical systems with an image in the virtual world and a real-world counterpart down on the shop floor. An efficient sensor data consolidation is in the position to establish self-learning control loops across global production networks in order to increase process robustness as well as process flexibility and thus allowing for instant product changes with an ideal lot size of one. Low-cost solutions for smart autonomous vehicles enable the breakup of classical production lines. One of the major challenges of these disruptive changes is securing the manageability of the possible data and information overflow. Novel socio-cyber-physical assistance systems will ensure the operation of these smart factories.
Keywords: Electronics production; Miniaturization; Sensor integration; Printing technologies; Autonomous and smart workpiece carrier; Self-Learning control loops; Socio-Cyber-Physical assistance systems

Data analysis and error detection in assembly lines using a three-dimensional visualization technique - Sand, Christian; Schuh, Patricia; Lechler, Tobias; Franke, Jörg (2017 7th International Electric Drives Production Conference (EDPC), 2017)
Usually, specific parameter ranges or tolerances are used to evaluate the quality of a process in serial production and especially in assembly processes [1]. Despite met tolerances along the whole assembly process, defective parts are produced due to malicious process parameter combinations. This paper presents a novel three- dimensional visualization technique to analyze and evaluate data from assembly processes and quality measurements in actuator manufacturing. It reveals correlations between process, energy and quality data in order to identify events which influence the quality of the final goo

Data and Power Distribution via Printed Electronics in Aerospace Applications - Gräf, Daniel; Ischdonat, Nils; Hedges, Martin; Hörber, Johannes; Franke, Jörg (European Microelectronics Packaging Conference EMPC2017, 2017)

Data continuity and traceability in complex manufacturing systems: a graph-based modeling approach - Kuhn, Marlene; Franke, Jörg (International Journal of Computer Integrated Manufacturing, 2021)
Modern industrial production systems are facing the challenge of interconnecting and exploiting the increasing amount of data from smart products, software systems, and IIoT devices. One of the main tasks in this context is the implementation of a data-continuous traceability system, which interconnects the heterogeneous data objects over the entire production flow. While traceability maturity is already high in regulated and process-driven industries, the established traceability solutions cannot be successfully applied to customized and volatile industries. In this research, a graph-based traceability modeling methodology is presented that allows the systematic development of data continuity and integration in manufacturing. Based on the traceability methodology, the graph data model and architecture are specified, which are aligned to the requirements of customized and complex manufacturing systems. The model is implemented and validated based on a Neo4j graph database for the use case of the manufacturing process of automotive electrical systems. This research overcomes the shortcomings of state-of-the-art traceability models by shifting the focus to the relationships between traceability-relevant data objects. The proposed graph-based traceability model is able to capture multi-hierarchical product structures and is less dependent on physical object identification, making it more applicable to customized and complex manufacturing.<br
Keywords: Traceability; mes; manufacturing information systems; data continuity; graph data model; neo4j

Data-driven quality monitoring of bending processes in hairpin stator production using machine learning techniques - Mayr, Andreas; Röll, Philipp; Winkle, Daniel; Enzmann, Maximilian; Bickel, Benjamin; Franke, Jörg (Procedia CIRP, 2021)
In the course of series production of high-performance automotive traction motors, the so-called hairpin technology is increasingly coming into focus. An essential process step is the bending of the hairpins, which is significantly influenced by variations in the wire material. Therefore, this paper will investigate how machine learning techniques can be used to monitor the dimensional accuracy of hairpins solely based on bending process data such as torque curves. In this way, deviations can be detected at an early stage and measures can be taken to prevent further rejects.
CRIS-Team Scopus Importer:2021-11-19
Keywords: artificial intelligence; bending process; electric motor production; hairpin technology; machine learning; prediction; quality monitoring

Data-driven quality monitoring of needle winding processes in electric motor production using machine learning techniques - Mayr, Andreas; Scheffler, Fabian; Fuder, Robert; Raffin, Tim; Kißkalt, Dominik; Franke, Jörg (Procedia CIRP, 2023)
Industry 4.0 is accompanied by various technologies, which offer great potential for optimizing today's manufacturing of electric motors. To meet high-quality standards and to enable further improvements, methods from artificial intelligence, in particular machine learning (ML), are recently moving into focus. Although needle winding is one of the most widely used processes for winding stators with inner slots, the potential of ML has not yet been tapped. Therefore, this paper introduces a novel, data-driven approach for quality monitoring of needle winding processes using ML techniques. To acquire quality-related process data, a common needle winding machine is equipped with suitable sensors first. Based on this, a proof of concept for an ML-based regression model aiming at predicting the coil quality solely based on process data is provided.
CRIS-Team Scopus Importer:2023-10-20
Keywords: artificial intelligence; electric motor production; machine learning; manufacturing; needle winding; predictive quality; quality monitoring

Data Farming in Production Systems - A Review on Potentials, Challenges and Exemplary Applications - Lechler, Tobias; Sjarov, Martin; Franke, Jörg (Procedia CIRP, 2021)
The current trend in production optimization extensively relies on data analytics methods such as statistics and machine learning algorithms, aiming at the exploration of undiscovered relationships in existing production systems. When real processes are monitored and analyzed, only the actually implemented features and relationships can be observed. This limits the amount of detectable interdependencies, since prolonged execution of defective processes is often avoided due to negative impact on the running production system. To discover additional insight into production systems, their digital representations i.e. the multi-domain simulation models can be leveraged. Based on these models, Data Farming allows to gain even more insight on production systems. First, major simulation experiments are executed automatically to generate new data sets. Second, the resulting data is analyzed using Data Mining methods to gain additional insight into simulation models and as a result knowledge over the real production system itself. Thus, using Data Farming approaches avoids test scenarios on the production system, which would lead to negative effects on productivity. At the same time, the quality of the simulation model, especially in its border areas, has to be precise enough to make valid statements on newly discovered interdependencies. This paper presents the current state of Data Farming applications in the context of production systems via a review on existing theory, applications and methods. On this basis, the potentials of Data Farming in the context of production systems as well as current challenges in its implementation are pointed out. In conclusion, new use cases for further work are presented.<br
Keywords: Data Farming; Production Systems; Simulation

Data fusion between a 2D laser profile sensor and a camera - Wagner, Maximilian; Heß, Peter; Reitelshöfer, Sebastian; Franke, Jörg (2015 12th International Conference on Informatics in Control, Automation and Robotics (ICINCO), 2015)
This paper describes a color extension of a 2D laser profile sensor by extracting the corresponding color from a camera image. For these purpose, we developed a routine for an extrinsic calibration between the profile sensor and the camera. Based on the resulting translation and rotation vectors a belonging pixel can be calculated for each profile point. Consequently, the color for each profile point can be extracted from the image. This approach is used to extend the geometric data of a robotic based 3D scanning system by color data.
Keywords: calibration; cameras; geometry; image colour analysis; image fusion; image resolution; image sensors; robot vision; 2D laser profile sensor; camera image; color data; color extension; data fusion; extrinsic calibration; image profile point extraction; robotic based 3D scanning system; rotation vectors; translation vectors; Calibration; Cameras; Image color analysis; Robot kinematics; Robot sensing systems; Three-dimensional displays; 3D Reconstruction; Calibration; Color Extension; Sensor Data Fusion; Workpiece Scanning

Data Mining System Architecture for Industrial Internet of Things in Electronics Production - Seidel, Reinhardt; Hassan Amada, Mohamadou; Fuchs, Jonathan; Thielen, Nils; Schmidt, Konstantin; Voigt, Christian; Franke, Jörg (2020 IEEE 26th International Symposium for Design and Technology in Electronic Packaging (SIITME), 2020)
Data collection and Machine Learning (ML) have already become reality in industrial applications. Also in electronics manufacturing, some successful approaches for the application of ML have been reported. However, for industrial applications, the infrastructure and the respective analysis-models for such approaches need to cope with the occurring data flow and structured storage in production. This contribution presents a cross-vendor data mining infrastructure setup that allows realtime tracking and structured storage of process data during operation in order to complement the material tracking of manufacturing execution systems (MES). Hence, the developed data mining system is the essential basis for real-time prediction use cases of ML in manufacturing.<br
Keywords: Manufacturing; Production; Servers; TCPIP; Data mining; Sockets; Protocols; Machine learning; Smart electronics manufacturing; Smart electronic module assembly; Data analytics; Electronics manufacturing

Decentralized Intelligence: The Key for an Energy Efficient and Sustainable Intralogistics - Scholz, Michael; Zhang, Xu; Kreitlein, Sven; Franke, Jörg (15th Global Conference on Sustainable Manufacturing, 2018)

Deep learning-based automated optical inspection system for crimp connections - Nguyen, Huong Giang; Meiners, Moritz; Schmidt, Lorenz; Franke, Jörg (2020 10th International Electric Drives Production Conference (EDPC), 2020)
Within the trend of electrification and autonomous driving, the significance of high-quality crimp connectors is increasing as they establish the electrical connection for the energy and information flow in the automotive system. Whereas the manufacturing of crimp connectors is highly automated, the final quality assessment mainly comprises manual optical inspection tasks that are human labor-intensive and time-consuming. Addressing this gap, a computer vision system to automate the final inspection of crimp connectors is proposed and implemented. In this paper, the image processing chain and the deep learning-based model to reason over image data of crimp connectors with regard to different defect classes are outlined. The effectiveness of this system using a dataset collected in the laboratory environment is demonstrated.<br
Keywords: crimp connectors; machine learning; optical inspection; quality management

Deep learning based cost estimation of circuit boards: a case study in the automotive industry - Bodendorf, Frank; Merbele, Stefan; Franke, Jörg (International Journal of Production Research, 2021)
Early cost estimation is a decisive value driver in the product development process in manufacturing industries. Machine learning offers new intelligent methods to support traditional cost calculation processes. While traditional research on intelligent cost estimation focuses on machine learning regression or classification models, we propose a new approach based on interlocking deep learning methods. In this paper we investigate the applicability of deep learning techniques, focusing on image recognition and deep learning regression as well as autoencoding to estimate product costs of circuit boards to be purchased. We create and evaluate deep learning models using real-world data from an original equipment manufacturer (OEM). Our findings suggest that deep learning models can streamline cost calculation and estimation processes while deep learning object recognition-based cost estimation outperforms autoencoding techniques. This research is designed to be transferable to other cost estimation projects.
CRIS-Team WoS Importer:2021-12-03

Deep learning-based optical inspection of rigid and deformable linear objects in wiring harnesses - Nguyen, Huong Giang; Franke, Jörg (Procedia CIRP, 2021)
The wiring harness is responsible for the information and energy flow within automotive vehicles and has become a safety-critical component within the trends of autonomous driving and electrification. As a result, the functionality, correctness, and traceability of the wiring harness need to be ensured with holistic quality assurance in the manufacturing. Addressing this research gap, this paper proposes an image processing pipeline for automated optical inspection of rigid and deformable linear objects in wiring harnesses. The deep learning-based optical inspection is outlined and implemented, the findings are presented, and the effectiveness and the relevance for industrial implementation are discussed.
Keywords: Automated optical inspection; automotive wiring harness; deep learning; image processing; segmentation

Defining Batches under Consideration of Quality-Related Factors for Improved Failure and Scrap Analysis - Baier, Lukas; Spindler, Simon; Wacker, Manuel; Franke, Jörg; Schuderer, Peter (Applied Mechanics and Materials, 2018)
Keywords: Batch Definition; Batch ID; Batch Number; Bulk Goods; Identification; Traceability

Demand-based dimensioning of compressed air systems for energy optimization and flexibility - Javied, Tallal; Kimmig, Florian; Franke, Jörg (Proceedings - 2018 4th International Conference on Control, Automation and Robotics, ICCAR 2018, 2018)
Due to high energy prices in Germany, manufacturing companies have an incentive to increase energy efficiency in production. Compressed air systems (CAS) offer high energy savings potentials. Studies show that CAS are poorly dimensioned in most cases. This paper describes the energy saving potential of compressed air systems. Additionally the importance of not only energy efficiency but energy flexibility is considered. To optimize the current systems and to determine need-based determination of CAS, a Software-tool was developed based on visual basic for application and MS Access. This tool is described in this paper. Different studies estimate a savings potentials due to efficient dimensioning at more than 15%. The described tool helps users identify their energy saving and flexibility potential and suggests CAS configuration to utilize the given potential. It illustrates different investment scenarios based on user-specific requirements. Users can evaluate alternatives that suit their needs based on different KPIs. This tool is designed for SMEs in order to allow them to analyze their CAS without requiring costly external consultation. Energy flexible CAS can enable users to Buy energy at lower costs and use it when prices are high. A smart factory can manage these control challenges independently and utilize the form of energy which is situationally most favorable. Thereby, both economical advantage and energy flexibility can be ensured.
CRIS-Team Scopus Importer:2023-03-07
Keywords: component; compressed air system; energy efficieny; energy flexibility

Demand-Side-Management by flexible generation of compressed air - Böhm, Ralf; Franke, Jörg (Procedia CIRP 63 ( 2017 ), 2017)
Industrial compressed air systems embrace significant potential for saving both energy and cost due to their share of approximately 7 % of the total industrial electricity consumption in Germany. As in electric energy systems based on renewable generation plants supply and demand often do not occur in the same period of time, volatile prices occur and demand side management is gaining importance. Decentralized automation offers opportunities in industrial environments for control of the equipment according to availability of electrical energy. Product-service systems on industrial plants supply manufacturing equipment with compressed air, nitrogen and other technical gases, which partly can be obtained from air by deposition processes. Those systems consist of air compressors, gas separators, reservoirs and lines. With suitable dimensioning and by equipping with automation technology those product-service systems can be used for demand side management purpose. In addition to basic operating parameters like current air pressure and status, those systems can process further information and create, for example, profiles on compressed air consumption over time. By enriching those profiles with data on pressure, volumes, system restrictions and current production requirements, the system control can identify the available potential for demand side management. Evaluation of operational strategies has to optimize conflicting objectives within the triangular relationship of storage design, control of the production according to price prospects and influencing or predicting the use of compressed air.
Keywords: Industrial compressed air systems; Energy flexibility

Der Digitale Zwilling als echtzeitnahes Fertigungsabbild - Selmaier, Andreas; Sjarov, Martin; Herbert, Meike; Distler, Johannes; Fürst, Jens; Franke, Jörg (Simulation in Produktion und Logistik 2021, 2021)
In the course of the fourth industrial revolution, a multitude of new digital applications are being introduced along the entire life cycle of production systems. The structures of the classic automation pyramid are being softened and replaced by hybrid and decentralised structures in order to allow data and information to flow flexibly directly to where they are needed. For decision making processes in the manufacturing environment, a comprehensive overview of the factory and its current state is crucial. For this, specialised solutions are required to provide people intuitive access to the digital factory. The digital representation including enrichment with actual data falls under the paradigm "digital twin", which in relation to mechatronic manufacturing systems can be systematized by means of the Digital Twin Structure Model (DTSM). The article discusses a corresponding solution in the "proof-of-concept" status. The underlying concept as well as a real-world application are presented accordingly. Furthermore, the added value and future potentials are laid out.<br
Keywords: Digitaler Zwilling; Digitale Fabrik; Industrie 4.0

Design and fabrication of a generic 3D-printed silicone unilateral cleft lip and palate model - Riedle, Hannah; Burkhardt, Andrea E.; Seitz, Vera; Pachaly, B.; Reid, Russell R.; Lee, Justine C.; Franke, Jörg (Journal of Plastic Reconstructive and Aesthetic Surgery, 2019)
The complexity of plastic surgery procedures often requires visualization of the anatomy in three dimensions and therefore demands the development of new and innovative teaching methods. This work describes the development and manufacture of a 3D silicone cleft lip and palate (CLP) model evaluated by surgical residents on its similarity to the biological model. Thirty unilateral CLP models were created and distributed to residents at two different institutions. The model was based on an adult CT scan that was manipulated to resemble an infant with a complete unilateral CLP. This digital model was directly printed in silicone elastomer pieces and later assembled. The residents rated the model based on its realistic value as well as whether or not they felt it improved their surgical technique. Twenty residents used the model to simulate a CLP repair. The structure of the model was rated as fairly realistic while both the material and assembly of the model require improvement in subsequent manufacturing. Post simulation, residents rated the model highly for how accurately it simulated the surgical procedure. An accurate 3D silicone unilateral cleft lip and palate replica was successfully created for educational purposes. This new approach combines a flexible generic design with automated manufacture.
CRIS-Team Scopus Importer:2019-08-30
Keywords: Cleft lip; Infant; Models; Reconstructive surgical procedures; Silicone elastomer; Surgery; plastic

Design and Fabrication of a Multi-Material Neurosurgical Simulator for an Endoscopic Third Ventriculostomy - Riedle, Hannah; Wittmann, Peter; Franke, Jörg; Rössler, Karl (BMEiCON 2019 - 12th Biomedical Engineering International Conference, 2019)
Haptic surgical simulators can improve skills and knowledge through experience. One possible application is the training of the high-risk procedure of an endoscopic third ventriculostomy (ETV) to treat an occlusive hydrocephalus. This study presents the development of a neurosurgical simulator optimized for automated manufacturing, while maintaining anatomical details and a variety of material properties. The core of the simulator is a 3D printed silicone model of the ventricular system, embedded in soft silicone gel, simulating the brain matter. Hard anatomical elements and a dynamic body fluid system complete the setup. The evaluation of the simulator by a medical expert shows that the anatomical geometries are realistic; the material properties however still need improvement.
CRIS-Team Scopus Importer:2021-04-20
Keywords: 3D printing; anatomical model; modelling; neurosurgery; surgical simulation

Design and simulation rules for printed optical waveguides with implemented scattering methods in CAD and raytracing software - Loosen, Florian; Backhaus, Carsten; Lindlein, Norbert; Zeitler, Jochen Tobias; Franke, Jörg (Proceeding, 117. DGaO-Jahrestagung, 2016)
The printing process of polymer optical waveguides is a new and uncharted research topic, which the research group OPTAVER is principally involved in. A main consequence of the printing process is the roughness of the interface between core and cladding. This surface between the dielectric media creates scattering in printed waveguides. To simulate this behaviour, standard non-sequential raytracing methods have to be extended with scattering algorithms. Here, scattering power spectra for each incident ray interacting with the rough surface are generated using the perturbation theory. Another task is to connect MID-speciﬁc CAD tools with raytracing simulations to create a holistic tool for design and validation of light propagation. This tool is specifically prepared to analyze the manufacturing process of polymer optical waveguides. This technique facilitates new applications in different research and development fields. Comparing the performances of real printed and simulated polymer optical waveguides is one of the major links between the different researchers of this DFG research group.
Keywords: Optisches Design; Optische Systeme; Optische Informationsübertragung

Designing an OPC UA based Ecosystem for Smarter Homes - Schäfer, Franziska; Bakakeu Ngassam, Romuald Jupiter; Kleinert, Bruno; Michl, Markus; Fey, Dietmar; Franke, Jörg (Advanced Engineering Forum 19, 2016)

Designing Manual Workplace Systems in Engineer-to-Order Enterprises to Improve Productivity: A Kano Analysis - Stoidner, Micha; Bründl, Patrick; Matthes, Tina; Nguyen, Huong Giang; Abrass, Ahmad; Franke, Jörg (SAE International Journal of Materials and Manufacturing, 2024)
Being an engineer-to-order (ETO) operating industry, the control cabinet industry faces difficulties in process and workplace optimizations due to changing requirements and lot size one combined with volatile orders. To optimize workplaces for employees, current literature is focusing on ergonomic designs, providing frameworks to analyze workplaces, leaving out the optimal design for productivity. This work thus utilizes a Kano analysis, collecting empirical data to identify essential design requirements for assembly workplaces, incorporating input from switchgear manufacturing employees. The results emphasize the need for a balance between ergonomics and efficiency in workplace design. Surprisingly, few participants agree on the correlation between improved processes and workspaces having a positive impact on their well-being and product quality. Ultimately, the study offers a list of requirements that are needed at ETO assembly stations to satisfy employees and improve efficiency of the production processes.<br
Keywords: Aerospace; Automotive; Commercial Vehicle; Optimization; Productivity; Personnel; Design processes; Supply chain management; Ergonomics; Production; Product development

Design of process parameters for the manufacturing of wrapped connections with single solid round wires using the explicit finite element analysis - Hefner, Florian; Praß, Julian; Kirchner, Philipp; Franke, Jörg (Procedia CIRP, 2020)
Keywords: process simulation; wrapped connections; explicit finite element analysis

Determination of equivalent transversely isotropic material parameters for sheet-layered lamination stacks - Baloglu, Maximilian Volkan; Ziegler, Marco; Franke, Jörg; Willner, Kai (Mechanical Systems and Signal Processing, 2020)
This paper covers the accurate prediction of equivalent homogenized material parameters for sheet-layered lamination stacks, which are located in rotors and stators of electric motors. Modeling the structural and dynamic behavior of these parts is a challenging task due to the special layered design of these stacks, with a huge influence of the applied joining technology, here a full-surface bonding. For the derivation of equivalent transversely isotropic material parameters, three procedures, namely the rule of mixture, an analytical and numerical homogenization, are compared eventuating in only minor differences between them. The investigations show that rather the input parameters for these averaging methods, i.e. the individual material parameters of each layer, are crucial for an accurate modeling. Experimental tests are carried out on coated sheet laminations to determine the initially unknown bonding varnish thickness with two different measurement methods, the 3D laser scanning microscopy and instrumented indentation testing, resulting in almost equivalent and reasonable values. The capability of the ab initio deduced material parameters is demonstrated by comparing an experimental and numerical modal analysis of a sample lamination stack showing an almost perfect agreement. By this, it is also revealed that a varnish Young's modulus measured by nanoindentation is overestimated from a macroscopic point of view. Damping parameters of a bonded lamination stack are determined with the help of the experimental modal analysis showing a relatively low damped system.
CRIS-Team Scopus Importer:2020-05-12
Keywords: Homogenization; Lamination stack; Laser scanning microscopy; Material modeling; Modal analysis; Nanoindentation

Determination of the Mechanical Properties of Aortic Tissue for 3D Printed Surgical Models - Riedle, Hannah; Mukai, Barbara; Molz, Pirmin; Franke, Jörg (BMEiCON - 2018, 2018)

Determination of the Mechanical Properties of Cardiac Tissue for 3D Printed Surgical Models - Riedle, Hannah; Molz, Pirmin; Franke, Jörg (2018 IEEE-EMBS CONFERENCE ON BIOMEDICAL ENGINEERING AND SCIENCES (IECBES), 2018)
CRIS-Team WoS Importer:2019-02-27

Determination of the Prospective Energy Consumption of Manufacturing Technologies with Methods-Energy Measurement (MEM) - Bornschlegl, Martin; Spreng, Simon; Kreitlein, Sven; Bregulla, Markus; Franke, Jörg (4th International Conference and Exhibition in Electric Drives Production E|DPC 2014, 2014)
The reduction of energy costs of manufacturing technologies is both an important and current objective for factory operators. But mostly, this idea to reduce the energy consumption is being implemented after the manufacturing technologies are installed. However, it would be more advantageous if efforts were made to save energy during the early planning process. To achieve an estimation of the energy consumption in this early planning stage, a new suitable forecast method is required. Therefore, this paper shows how the prospective energy consumption can be determined by using Methods-Energy Measurement (MEM). Based on the needs of production planners, future challenges and requirements for MEM are listed. Further-more, the concept of basic energy elements and their value determination techniques are introduced, and different possibilities are outlined and assessed. For an easier determination of the energy demands of a complex production cell or manufacturing equipment, standard equipment patterns will be designed. This template supports both planners and decision-makers to create reliable and standardized Resource Performance Indicators (RPI). Subsequently, the architecture of the MEM-calculation model is presented. This approach enables a holistic estimation of the energy consumption of manufacturing technologies and leads to higher levels of transparency. Furthermore, MEM contributes to identify and realize sustainable solutions in advance and as a result, increases the profitability of a factory.
Keywords: Methods-Energy Measurement; MEM; energy consumption; energy efficiency; green design; production planning

Development and application of load profiles for thermal qualification testing of receptacle automotive connectors - Friedlein, Matthias; Gräf, Daniel; Stegner, Jonas; Franke, Jörg (MP Materials Testing, 2021)
Receptacle contacts often are a weak spot of the reliability in electronic systems. During the application phase of the lifecycle, especially in the automotive wiring harness, connectors experience severe loads such as temperature changes. During qualification testing, accelerated tests simulate these thermal stresses. Yet, only the damage mechanisms relevant for service life must be triggered. However, the increasing complexity of electronic components and wiring harnesses demands a continuous adaptation of test strategies. Therefore, this study develops and applies application-oriented load profiles for thermal qualification testing of connectors. Experiments include load profiles inspired by seasonal changes and daily car usage. The tests are carried out on a relative movement test bench as well as in a thermal cycling testing chamber. Contact resistance progression curves, the surface roughness of the contacts, and the area of the stressed contact zones assist in evaluating the effectiveness of the load profiles. All contacts tested during relative movement experiments show no change in contact resistance. The thermal cycling load profile however results in a significant rise in contact resistance. Additionally, the roughness values show varying damages on the contacts due to the different load profiles.
CRIS-Team WoS Importer:2021-04-30

Development and implementation of a software layer for generic skill descriptions of versatile autonomous vehicles - Scholz, Michael; Kraus, Patrick; Franke, Jörg (Procedia CIRP, 2020)
This paper describes a control architecture for versatile autonomous vehicles (VAV). As a part of a hybrid architecture, a behaviour engine is developed which offers two main skills, forecast and acting, which are used for order coordination and execution. Furthermore, we introduce time dependent Key Performance Indicators (KPIs) as basic information quantities. These KPIs are transmitted as scheduled values for order coordination and as real values after the execution to offer feedback on the performance of the VAV. An experimental setup shows that the architecture is well suited for a VAV.
CRIS-Team Scopus Importer:2021-04-19
Keywords: Software architecture; Software layer; Versatile autonomous vehicles

Development and Test of a Data Framework for Prediction of Soldering Quality in Selective Wave Soldering Applying K-Nearest Neighbors - Seidel, Reinhardt; Thielen, Nils; Schmidt, Konstantin; Voigt, Christian; Franke, Jörg (2020 IEEE 26th International Symposium for Design and Technology in Electronic Packaging (SIITME), 2020)
Machine Learning has been proven to be a powerful tool to model and predict complex applications. Selective wave soldering is a widely applied interconnection technology for THT components. It is mostly used if components are not substitutable by surface mount devices due to high thermal load or mechanical stress. Especially in power electronic circuit boards, large copper layers or high thermal mass components lead to critical soldering situations. This paper suggests a Machine Learning framework to identify thermally challenging solder joints. The hybrid approach consisting of an analytical thermal description of THT components and solder joints in the multilayer circuit board and the ML analysis allows the prediction of arbitrarily complex solder joint configurations. The data framework represents electronic components and solder joints. Utilizing solder joint, component and soldering process parameters as input, the K-Nearest Neighbors algorithm predicts the probable hole fill following IPC-A-610 with an overall accuracy of about 75%.<br

Development and validation of a digital twin framework for SMT manufacturing - Seidel, Reinhardt; Rachinger, Ben; Thielen, Nils; Schmidt, Konstantin; Meier, Sven; Franke, Jörg (Computers in Industry, 2023)
Electronics manufacturing is a global industry and key to innovation in the virtual world because it is the physical backbone. The cost-effective development and manufacture of such electronic modules are critical to maintaining the competitiveness of high-wage manufacturing countries. Therefore, two approaches suggest themselves: Design for Manufacturing (DfM) and manufacturing optimization. To apply both approaches in in-dustry, it is necessary to introduce models that describe the relationship between process input and process output. Applied to electronics manufacturing processes, this means that design, process parameters, and material properties must be mapped to process quality criteria in end-of-line testing. Recently, machine learning (ML) algorithms have been emerging and dominating other modeling methods such as numerical simulation. To develop such complex ML models, a unified data structure for each input and output must be defined. This paper proposes an extensible ML-enabled framework that provides direct and structured access to the printed circuit board (PCB) design and process parameters. This framework is used to perform structured data acquisition using a custom data mining board. During the manufacturing of these PCBs on a full surface mount technology (SMT) process line, all available process machine-level data is collected, archived, and parsed into a uniform, stan-dardized, and flat data structure. This enables fast analysis of the correlation between inputs and quality criteria, direct access by ML algorithms, and training of models. Through these measures, the quality of the framework is validated and correlations are revealed and compared to previous literature. This shows the great importance of a data framework for the integration of data analysis technologies into industrial processes.
CRIS-Team WoS Importer:2023-01-13

Development and Validation of a Material Application Tool for the Covering Process of a Wire Harness - Heisler, Paul; Hausecker, Erik; Regler, Johannes; Süß-Wolf, Robert; Franke, Jörg (2020 10th International Electric Drives Production Conference, EDPC 2020 - Proceedings, 2020)
The wiring harness production in the automotive sector is still characterized by a high proportion of manual work. In particular, the process of taping the wire harness on the assembly boards with conventional adhesive tape is a very time-consuming manual work step. In order to automate this, various methods have already been tested and one of the most promising is the dosing process. Thereby a nozzle moves along the routed cables and covers them with silicone rubber. In order to apply this process successfully in practice, it is particularly necessary to sheat variable wire harness geometries that differ in terms of their diameter and composition. In scope of this work, a nozzle was developed, which can be infinitely adjusted to different cable strands using an iris diaphragm mechanism. The fused deposition modelling (FDM) process was used for fast production and testing of various nozzle construction. In addition to various cable harnesses, concepts were developed and validated in order to cover nodes or branch points with the dosing process. All experiments were carried out in the form of model tests in terms of their applicability in practice.
CRIS-Team Scopus Importer:2023-03-07
Keywords: automation; automotive industry; dosing process; silicone rubber; taping; wiring harness; wiring harness production

Development of a control system for a universal winding machine based on virtual path planning - Mahr, Alexander; Wurm, Markus; Bickel, Benjamin; Franke, Jörg; Halder, Hubert (2017 7th International Electric Drives Production Conference (EDPC), 2017)
For the flexible production of increased efficient electric drives new production machines are needed. To this end a new, highly flexible winding machine, which can be used for a broad range of different windings, is presented. The use of two kinematic chains facilitates a higher degree of freedom than conventional machines in this sector. In addition to the mechanical flexibility of the machine, the path planning must be simple and intuitive. The software for path planning is based on the principle of a CAD-CAM chain, as it is also used with robot kinematics. In order to enable these functionalities, a special programming method for PLC- and CNC core is require
Keywords: E|DRIVE; Automated Winding Assembly; Stator; Key Words: Robot-based

Development of a lightweight hardware for controlling multiple dielectric elastomer actuators - Landgraf, Maximilian; Reitelshöfer, Sebastian; Yoo, In Seong; Franke, Jörg (4th International Conference on Electromechanically Active Polymer (EAP) Transducers & Artificial Muscles, 2014)
Keywords: B|Mech

Development of a low cost anthropomorphic robotic hand driven by modified glove sensor and integrated with 3D animation - Ariyanto, Mochamad; Ismail, Rifky; Nurmiranto, Ahmad; Caesarendra, Wahyu; Paryanto,; Franke, Jörg (IECBES 2016 - IEEE-EMBS Conference on Biomedical Engineering and Sciences, 2016)
In this paper, a low cost anthropomorphic robotic hand is developed using low cost materials. The robotic hand has 6 joints and 6 actuators. User or operator gives the hand movement command by a modified glove sensor. The glove consists of six flex sensors placed on the fingers and wrist join that detect the bend of the fingers into a joint angle in each finger. 3D CAD model of robotic hand is exported into SimMechanics model using SimMechanics link to generate SimMechanics block diagram that can run in MATLAB/ Simulink environment. The model in SimMechanics is utilized as 3D animation hand. The relationship of the servo motor rotation angle among metacarpal phalangeal (MCP), proximal inter phalangeal (PIP) and distal inter phalangeal (DIP) joints will be presented. Finally, the performance of robotic hand is tested to grasp various objects and to perform specific motion augmented with 3D animation. The experiment results show the successful development of a low cost anthropomorphic robotic hand that can perform activities of daily living (ADLs).
CRIS-Team Scopus Importer:2023-03-07
Keywords: 3D animation; anthropomorphic; flex sensor; robotic hand; SimMechanics

Development of an adjustable measuring system for electrical consumptions in production - Spreng, Simon; Kohl, Johannes; Franke, Jörg (Applied Mechanics and Materials, 2014)
The establishment of green products and a sustainable production increasingly affects corporate competitiveness, as an efficient production does not only affect the energy costs, but also improves the company image. As the importance of renewable energy sources increases, mainly providing unsteady energy levels, load management of manufacturing and assembly lines fades into spotlight. For this purpose, proper measuring equipment is required, being able to log and evaluate varying energy loads.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Electrical consumption; Energy management; Measuring system; OPC UA

Development of an Intelligent System to Strengthen Cognitive and Motor Skills in the Home Environment - Bauer, Jochen; Kettschau, Anna-Katharina; Brücher, Bastian Alexander; Bodendorf, Frank; Skibbe, Alexander; Rashid, Ria; Franke, Jörg (Advanced Engineering Forum, 2016)

Development of a test bench for the urodynamic simulation of the lower urinary tract* - Yoo, In Seong; Preis, Alexander; Franke, Jörg (2020 42nd Annual International Conference of the IEEE Engineering in Medicine & Biology Society (EMBC), 2020)
Stress urinary incontinence restricts the quality of life of affected individuals. To restore continence and increase the quality of life in a long term, the currently applied surgical treatment methods for more severe cases are not sufficient. To support the development of a novel intraurethral artificial sphincter with the goal to replace current systems, a test bench is developed, which simulates the lower urinary tract with regards to its urodynamics. To verify the ability of the implant to maintain continence and allow undisturbed micturition, pressure and flow conditions of the lower urinary tract are reproduced, with the option to automatically conduct test cycles.Clinical relevance- The developed test bench accurately replicates the urodynamics of the lower urinary tract and therefore allows the validation of intraurethral systems.<br
Created from Fastlane, Scopus look-up
Keywords: biological fluid dynamics; biomechanics; biomedical equipment; medical device evaluation; simulation

Development of Magnetic Sheets for CO2 Efficient Electric Drives Using an Additive Manufacturing Approach - Schmidt, Alexander; Ziegler, Marco; Franke, Jörg; Kühl, Alexander (Lecture Notes in Mechanical Engineering, 2023)
Climate change and its negative consequences for the environment are the greatest challenge of the current era. Electric machines are considered key both for the generation of regenerative electricity and as a substitute for fossil fuels in industry and fossil engines in the transportation sector. Resource-efficient manufacturing and operation of electric machines are therefore of high importance. The central component of every electric machine is the soft magnetic core. The manufacturing process and material selection are influencing the iron losses during operation. This paper presents a novel technology for manufacturing magnetic sheets and lamination cores for carbon dioxide efficient electric drives using an additive manufacturing approach. The potential of the technology is explained and the challenges in process development are highlighted.
CRIS-Team Scopus Importer:2023-07-14
Keywords: Additive Manufacturing; Electric Motor; Electrical Steel; Magnetic Sheets; New materials; Sustainable Manufacturing

Development of Magnetic Sheets for CO2 Efficient Electric Drives Using an Additive Manufacturing Approach - Schmidt, Alexander; Ziegler, Marco; Kühl, Alexander; Franke, Jörg (Springer Science and Business Media Deutschland GmbH, 2023)
Keywords: Magnetic Sheets; New materials; Electric Motor; Electrical Steel; Sustainable Manufacturing; Additive Manufacturing

Development of new extensible components for enabling a more flexible usage of jamming-gripper - Shahsevani, Rasool; Reitelshofer, Sebastian; Bodaghi, Mohammad Ali; Franke, Jörg (IEEE International Conference on Robotics and Biomimetics, ROBIO 2019, 2019)
In many applications, gripping systems are key elements to turn industrial robots into flexible and versatile handling systems. Depending on the gripping principle those systems can either be rather limited or very flexible in terms of gripping a broad variety of different objects. The so-called jamming-gripper can grasp a wide range of objects by passively adapting to the shape of different workpieces. The purpose of the work described in this paper is to develop extensible components for optimizing the jamming-gripper. Concerning the previous jamming-gripper, the problems related to a mechanical structure, installing a filter, a balloon as a membrane, and filling the balloon with powder are investigated to improve the jamming-gripper system. A new gripper system designed is presented to not only address the existing problems but also to make it even more userfriendly and practical. Tests are performed to determine the influence of three different filling ratios of the membrane on the gripping performance for objects with complex geometries.
CRIS-Team Scopus Importer:2020-02-21
Keywords: Extensible; Extensible Components; Gripper; Gripper system; Jamming; Jamming-Gripper; Membrane

Development, qualification and optimization of innovative contacting methods in the field of electric drives production - Gläßel, Tobias; Spahr, Michael; Spreng, Simon; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2016)
Regarding the demands for newly developed engine designs as well as the production related requests for processes enabling flexible mass production, the dynamic field of electrical engine production is facing more and more needs to utilize optimization potentials. As these needs especially influence the stator contacting process, the institute FAPS introduced the research group contacting technologies, which uses a multidimensional approach to obtain the complexity of the regarded research field. Here, not only already existing technologies are further optimized but also new technologies are developed and qualified.

Die elektronische Gesundheitsakte in der intelligenten Wohnung - Bauer, Jochen; Kettschau, Anna-Katharina; Blank, Andreas; Wiebe, Sergej; Franke, Jörg (8. Deutscher AAL-Kongress, 29.-30. April 2015, Frankfurt am Main, Tagungsbeiträge, 2015)
Keywords: AAL; E|Home; Medizin; Smart Home

Die intelligente Wohnung als Baustein im Internet der Dinge: Potenzialanalyse und Konzept einer domänenübergreifenden Lösung - Bauer, Jochen; Kettschau, Anna-Katharina; Michl, Markus; Bürner, Johannes; Franke, Jörg (Erste Transdisziplinäre Konferenz zum Thema Technische Unterstützungssysteme, die die Menschen wirklich wollen, 2014)
Keywords: AAL; E|Home; Energie; Smart Home

Dielectric elastomer actuators as self-sensing devices: A new method of superimposing actuating and sensing signals - Landgraf, Maximilian; Zorell, Ulrich; Wetzel, Thomas; Reitelshöfer, Sebastian; Yoo, In Seong; Franke, Jörg (SPIE Smart Structures NDE, 2015)
Keywords: dielectric elastomer actuator; dielectric elastomer sensor; self-sensing actuator; superimposition of actuating and sensing signals

Dielectric elastomer actuators - On the way to new actuation-systems driving future assistive, compliant and safe robots and prostheses - Reitelshöfer, Sebastian; Landgraf, Maximilian; Yoo, In Seong; Hörber, Johannes; Ramer, Christina; Ziegler, Christian; Franke, Jörg (5th IEEE RAS/EMBS International Conference on Biomedical Robotics and Biomechatronics, 2014)
For almost 20 years, dielectric elastomer actuators (DEAs) have been the subject of intense research in material science. A large number of publications describe artificial muscles based on DEAs as a promising alternative for an energy efficient, lightweight and flexible actuation architecture. DEAs could improve and extend the capabilities of robotic and prosthetic devices in terms of their dynamical performance and their eligibility for energy autarkic operation. However, up to now DEAs are not available on a large scale with reproducible characteristics nor are they yet usable on a system integration level. In this paper we present recent findings of our ongoing five-year project to qualify DEAs as feasible artificial muscles for usage in compliant robot kinematics and soft prosthetic devices. The focus of this contribution lies on a new automated production process using Aerosol Jet Printing for stacked DEAs with very thin layers for reduced driving voltages and improved mechanical characteristics resulting from the additive manufacturing. Secondly, a new set of lightweight power electronics based on pulse width modulation (PWM) is presented which aims at the improvement of the overall specific power of DEA driven kinematic systems.
Keywords: compliant mechanisms; electroactive polymer actuators; prosthetics; robot kinematics; DEA driven kinematic systems; PWM; actuation systems; additive manufacturing; aerosol jet printing; artificial muscles; assistive robots; automated production process; compliant robot kinematics; dielectric elastomer actuators; lightweight power electronics; pulse width modulation; safe robots; soft prosthetic devices; Biomechatronics; Conferences; Robots

Differentiating Industrial Internet of Things platforms from a value network-oriented perspective - Hartner, Fabian; Löwen, Ulrich; Franke, Jörg (Procedia CIRP, 2021)
Currently, there are seven so-called platform companies among the ten most valuable companies in the world. Companies such as Google, Amazon and Apple have established themselves as successful platforms in the business-to-consumer (B2C) market. Due to the digitalization of products, production systems and processes, the topic of digital platforms is also becoming increasingly important in the manufacturing industry. In order to compete against global challenges and increasing competition, companies are currently launching new data-based services (e.g. machine downtime prediction), as-a-service-offerings or own Industrial Internet of Things (IIoT) platforms. However, initial analyses already show that a simple transferability of insights from B2C to industrial business-to-business (B2B) market is not directly feasible. The potential for these use cases to generate business effects between the different roles involved (e.g. in two-sided markets) needs to be investigated transparently. This publication uses a value network methodology to analyze platform examples from the manufacturing industry and differentiate them with regard to their value propositions and addressed market-sides. From this, new insights into the differentiation of mechanisms and dynamics can be derived, which are crucial for the success of digital platform operators as new business roles in the value network of manufacturing industries.
Keywords: IIoT platform; Digital Platforms; Manufacturing Industry; Value Networks; Two-sided markets

Digital Industrial B2B Platform Patterns From A Business Perspective - Hartner, Fabian; Löwen, Ulrich; Franke, Jörg (Proceedings of the 2nd Conference on Production Systems and Logistics (CPSL 2021), 2021)

Digitalisierung im Engineering – Ein Ansatz für ein Vorgehensmodell zur durchgehenden, arbeitsteiligen Modellierung am Beispiel von AutomationML - Schäffer, Eike; Penczek, Lars; Mayr, Andreas; Bakakeu Ngassam, Romuald Jupiter; Franke, Jörg; Kuhlenkötter, Bernd (Industrie 4.0 Management : Gegenwart und Zukunft industrieller Geschäftsprozesse, 2019)
Die Digitalisierung im Engineering verspricht automatisierte Arbeitsabläufe, höhere Geschwindigkeiten und sinkende Kosten bei der Entwicklung von Automatisierungslösungen. Voraussetzung hierfür ist nicht nur die Modularisierung auf Basis einer strukturierten Beschreibungssprache, sondern auch eine einheitliche, aufeinander aufbauende Modellierung, welche einen automatisierbaren Datenaustausch über die Systemgrenzen hinweg ermöglicht. Um eine breite Anwendung zu erzielen, sollte die zugrundeliegende Ontologie auf bestehenden Normen und Standards aufbauen und in Open-Source-Anwendungen zur Verfügung stehen. Für die kollaborative und konsistente Entwicklung einer solchen Ontologie bedarf es eines strukturierten, methodischen Vorgehens sowie einer damit verbundenen Modellierungslandkarte, welche als Orientierung zur standardisierten, arbeitsteiligen Modellierung dient. Ein möglicher Ansatz für das benötigte Vorgehensmodell sowie der zugehörigen Landkarte wird im Rahmen dieses Beitrags vorgestellt und unter Verwendung von AutomationML validiert. Der vorgestellte Ansatz soll eine mögliche Richtung aufzeigen und weitere prozessgesteuerte Modellierungsbestrebungen von Ontologien anregen. Digitization in engineering promises automated workflows, higher speed and lower costs in the development of automation solutions. The prerequisite for this is not only modularization based on a structured description language, but also uniform, interdependent modeling that ensures automated data exchange across system boundaries. In order to achieve a broad application, the underlying ontology should be based on existing norms and standards and be available in open source applications. However, the collaborative and consistent development of such an ontology requires a structured, methodical procedure and an associated modelling map that serves as an orientation for standardized, work-sharing modelling. A possible approach for the required procedure model and the related map will be presented in this article and validated using AutomationML. The presented approach should point out a possible direction and stimulate further process-controlled modelling efforts of ontologies.<br
Keywords: Durchgängiges Engineering; AutomationML; Modularisierung; Standardisierung; maschineninterpretierbar; Modellierungsmethoden; continuous engineering; modularization; standardization; machine interpretable; modelling methods

Digitalization and Adoption of Industry 4.0 in Engineer-to-order Small and Medium-sized Manufacturing Companies: An Empirical Analysis - Bründl, Patrick; Stoidner, Micha; Nguyen, Huong Giang; Baechler, Andreas; Franke, Jörg (2023 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM), 2023)
Industry 4.0 marks a significant shift in manufacturing practices, deeply influencing small and medium-sized enterprises (SMEs) in the engineer-to-order (ETO) sector. This study delves into the impact of digitalization and Industry 4.0 adoption in ETO SMEs, specifically within control cabinet manufacturing. A web-based survey was conducted to explore perceptions of digitalization, perceived advantages, and implementation obstacles of 14.0. Results indicate that ETO SMEs generally perceive digitalization as an opportunity for growth and transformation, expecting notable benefits such as increased efficiency, improved data management, and enhanced product quality. Yet, the study also identified obstacles such as high costs, lack of technical expertise, and cybersecurity concerns. This paper underscores the transformative potential of digitalization and I4.0 within the ETO manufacturing sector, stressing the need for comprehensive support systems and educational initiatives to help SMEs navigate the digital transition, enhance their competitiveness, and ensure their sustain ability in the I4.0 era.<br
Keywords: Costs; Navigation; Product design; Fourth Industrial Revolution; Quality assessment; Computer security; Business; Control cabinet; Digitalization; Engineer-to-Order; Information technology; Industry 4.0; Small and medium-sized enterprises

Digitally enabled supply chain integration through business and process analytics - Bodendorf, Frank; Dentler, Simon; Franke, Jörg (Industrial Marketing Management, 2023)
Supply chain integration (SCI) is the degree to which a manufacturer strategically collaborates with its supply chain partners and collaboratively manages intra- and inter-organizational processes to gain superior operational performance. Grounded on system theory, contingency theory, and knowledge based view this paper identifies requirements for successful SCI. In alignment with the findings of a qualitative case study by expert interviews and participant observations the study demonstrates that a lack of organizational compatibility, a lack of supply chain planning, and a lack of information sharing are the main barriers for successful SCI, which can be compensated by the positive aspects of an increase of organizational IT capability focused on intelligent systems, which play a key role for successful SCI. By an additional quantitative empirical study, we show how these systems, more specifically artificial intelligence (AI) empowered process mining (PM), could compensate for the identified deficiencies. Subsequently we implement a graph convolutional network (GCN) in order to predict the next process activity and its corresponding timestamp in the product development process supporting SCI. Based on the qualitative and quantitative results we discuss implications both for theory and practice.
CRIS-Team Scopus Importer:2023-08-11
Keywords: Multi-method; Performance; Process analytics; Supply chain integration

Digital Twin of the Linear Winding Process Based on Explicit Finite Element Method - Weigelt, Michael; Kink, Julian; Mayr, Andreas; von Lindenfels, Johannes; Kühl, Alexander; Franke, Jörg (2019 9th International Electric Drives Production Conference (EDPC), 2019)

Disassembly, recycling, and reuse of magnet material of electric drives - Klier, Tobias; Risch, Florian; Franke, Jörg (Proceedings - 2013 IEEE International Symposium on Assembly and Manufacturing, ISAM 2013, 2013)
The paper discusses different automation concepts for the disassembly of surface mounted magnets, and for the removal of the bandaging of rotors. In detail three strategies to recover the magnet bodies of rotors will be presented. Furthermore the paper introduces an innovative disassembly machine, which can handle different variants of the targeted magnets, to avoid the troubles during the manual removal of magnetized magnets from rotors with surface mounted mag-nets. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Disassembly; Magnet; Rare Earths; Recycling; Sustainability

Disassembly strategies for recovering valuable magnet material of electric drives - Klier, Tobias; Risch, Florian; Franke, Jörg (2013 3rd International Electric Drives Production Conference, EDPC 2013 - Proceedings, 2013)
The paper discusses different automation concepts for the disassembly of magnetized magnet bodies from rotors, and for the removal of the bandaging of rotors. In detail three strategies to recover the magnet bodies of rotors will be presented. Furthermore the paper introduces an innovative disassembly machine, which can handle different variants of the targeted magnets, to avoid the troubles during the manual removal of magnetized magnets from rotors with surface mounted magnets. The paper also presents a concept for recovering internal permanent magnets. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Disassembly; Magnet; Rare Earths; Recycling; Sustainability

Discrete event simulation of individual energy consumption for productvarieties - Kohl, Johannes; Spreng, Simon; Franke, Jörg (Procedia CIRP, 2014)
Load management systems are increasingly being used in companies to reduce the energy costs of production. However, the success of a load management system depends on the quality of the energy consumption estimation. The present approach illustrates the potential to predict the energy consumption of individual products and their variants without the need for setting up a new data model. For this purpose, a methodology is developed for upgrading any existing material flow model with energetic aspects. The aim of the related work is the generation of a nonredundant data model with low modeling efforts for the user. ©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: Discrete event simulation; Energy modelling; Load forecasting for facilities; Load management for product varieties; Prediction of energy consumption

Distributed Camera Architecture for Seamless Detection and Tracking of Dynamic Obstacles - Scholz, Michael; Steinkamp, Jan; Zwingel, Maximilian; Hefner, Florian; Franke, Jörg (Procedia CIRP Volume 91, 2020)
Tracking of dynamic objects is a key element especially for in-door logistic solutions but also for e.g. manufacturing plants and warehouses. This paper is dealing with a tracking approach which is based on multiple cameras that are permanently mounted on the ceiling. In comparison to currently applied methods of detecting and tracking dynamic objects in the field of AGVs this approach is innovative. This is due to the shift in the capture of tracking data to ceiling cameras exclusively, for the reason of gaining a holistic overview of the complete tracking area. The application case discussed in this paper is for AGVs in the frame of a research project. However, this approach can be applied for different use cases which require a pursuit and tracking of dynamic objects that is based on multiple cameras.
Keywords: logistics; Flexible manufacturing system (FMS); Distributed design

Distributed Condition Monitoring Systems in Electric Drives Manufacturing - Fleischmann, Hans; Spreng, Simon; Kohl, Johannes; Kißkalt, Dominik; Franke, Jörg (Electric Drives Electric Drives Production, 2016)
In industrial manufacturing, high system availability is the most effective lever for increasing productivity. For minimal downtimes, it is important to identify sources of errors at an early stage in order to perform scheduled maintenance. Especially in the field of electric drives manufacturing, the thermo-crimping process is one major technology to join insulated copper wires with belonging current carrying parts. However, due to its operating principle, this technology has to be associated with strong disadvantages. Primarily, the excessive tool abrasion leads to immoderate, difficult to plan maintenance operations. In order to address these challenges, this paper introduces a generic condition monitoring system, which is the enabler for predictive maintenance and online product quality monitoring in this area. By recognizing variations in energy consumption and process temperature, it is possible to determine the wear margin of electrodes and the joint quality during operation. According to the Industrial Internet of Things (IIoT), the implementation relies on the communication standard Open Platform Communications Unified Architecture (OPC UA). Finally, verification and validation are performed in a case study.
Keywords: Condition Monitoring Systems; Data Mining; Predictive Maintenance; Thermo-Crimping Processes; OPC UA

Distributed Software Architecture for AGVs for Separation of Dynamic and Static Obstacles - Scholz, Michael; Lieret, Markus; Bigott, Marc; Franke, Jörg (Procedia Manufacturing 38, 2019)
The current trend towards mass customization confronts established mass production systems with specific challenges. In future production layouts will have to provide a high degree of flexibility and changeability in order to be able to respond to the demand for individualized mass products. This leads to a production network in which the work schedule of each product and thus the sequence of the individual production resources are flexibly arranged. A challenge in this scenario is the implementation of material transport between the machines. The use of mobile transport robots to realize a flexible connection of all material sources and sinks proves to be effective. However, the current design forms, as a monolithic AGV system or the use of flexible autonomous units, show specific weaknesses. The paper describes the research approach to establish an intralogistics service-based software architecture as an intralogistics execution system, which contains the elementary functions of a cross-platform use of mobile autonomous systems. One key application is to digitize the workspace of the mobile systems with a distributed system of infrastructural sensors. An embedded unit separates the scenario into static and dynamic obstacles. The method discussed also includes the aggregation of the images with static obstacles to a world model as a basis for global cross-platform routing. Thus, it is possible to include the static obstacles in an early phase of path planning. The researched architecture integrates a routing service, which offers a cross-platform map for each type of transport robots in use. The dynamic obstacles of the respective scenery are tracked directly by the embedded decentralized ceiling sensors. By combining the Hungarian method with a Kalman filter, the trajectory of the detected dynamic obstacles can be determined. Within the discussed method, this information is transmitted directly from the sensor units to the autonomous systems and allows the local path planner to avoid collisions. Within the implementation of both methods in an industrial demonstrator, the functionality of both services could be validated. The necessary real-time capability for a valid collision avoidance was not achieved due to the computing capacities in us

Distributed Software Architecture for Type-Specific AGV Routing - Scholz, Michael; Degel, Martin; Franke, Jörg (Tagungsband des 4. Kongresses Montage Handhabung Industrieroboter, 2019)
The current trend towards mass customization confronts established mass production systems with specific challenges, as these are designed for the production of large quantities with a small number of variants. Future production layouts will have to provide a high degree of flexibility and changeability in order to be able to respond to the demand for individualized mass products. This leads to a production network in which the work schedule of each product and thus the sequence of the individual production resources are flexibly arranged without losing the cost advantages of mass production. The current design forms, as a monolithic AGV system or the use of flexible autonomous units, show specific weaknesses that limit the use of these solutions in a flexible production network. The paper describes the research approach to establish an intralogistics service-based software architecture as an intralogistics execution system, which contains the elementary functions of a cross-platform use of mobile autonomous systems. One key application is the implementation of typespecific routes, which enables the cross-platform digitalization of the workspace to improve the interoperability and efficiency in route and path planning of different transport solution within one scenario. The implementation of the approach shows the advantages of a cross-platform service structure in general and the routing service in particula
Keywords: AGV; Service-Based Intralogistics Execution System; Routing Service

Dynamic Light Control Using Bionic Dielectric Elastomer Iris Actuators - Martin, Sina; Bruns, Arne; Franke, Jörg (Advanced Functional Materials, 2022)
Apertures are used in optical systems to limit the luminous flux. In the human eye the iris serves this purpose but can be damaged requiring an implant, which to date is static, limiting the optical performance. The authors thus report the development of a prototype demonstrating the feasibility of a flexible dynamic iris implant manufactured with an automated manufacturing technique. The presented actuators are printed via aerosol jet printing allowing a high reliability in produced electrode quality. Through optimization of the actuator design for maximum contraction they demonstrate a pupil area reduction of 13.40% or 6.94% reduction of pupil diameter, respectively. Thereby the prototype demonstrates an illuminance reduction of 18.25% in the central visual axis. Furthermore, they present a first iteration of a bionic closed-loop control mimicking the human iris reflex thus laying the foundation for a self-controlled iris implant.<br

E|Benchmark - A pioneering method for energy efficient process planning and assessment along the life cycle process - Kreitlein, Sven; Schwender, Sabrina; Rackow, Tobias; Franke, Jörg (Procedia CIRP, 2015)
This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production from the perspective of production planning. Production planning is an organizational entity within an enterprise and deals with the creation and provision of all production relevant documents and equipment in order to achieve maximum efficiency through a minimum of resources and effort. The tasks of production planning are evaluated by means of their relevance for an energy efficiency comparison. For this, evaluation criteria are determined that consider influences on the production processes and basic goals of production. This is necessary due to the fact that tasks of production planning cannot be evaluated directly via energy consumption and energy efficiency. This results in 12 tasks through which a high leverage effect for a more energy efficient production can be achieved. Another possibility for an energy efficiency evaluation is presented via the approach of minimal value calculation. The underlying concept is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. By linking the minimum value calculation to the production planning, a predetermination of the theoretical energy consumption - And thus an energy efficient planning - is possible. The resulting energy saving potentials extend over the entire life cycle of a process and enable savings of an increasing energy amount.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficiency; Process forward-planning; Sustainable manufacturing

E|Benchmark - A pioneering method for process planning and sustainable manufacturing strategies - Kreitlein, Sven; Spreng, Simon; Franke, Jörg (Procedia CIRP, 2015)
This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production. A directive for energy efficiency benchmarking has already been published, however, due to its lack of defined energy indicators, it does not allow for a significant comparison. In a preliminary step, 120 currently used energy indicators were examined to assess their suitability as an energy benchmark. Based thereon, three approaches for the assessment of energy efficiency of the manufacturing processes in the production as well as a method for transferring the system by means of relevant indicators at the sectorial and corporate levels were developed. In the following, the approach of "minimal value calculation," which was identified as being the most advantageous, is presented in detail. The basic idea is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. Depending on the analysis of influencing factors, a model highlighting their dependencies could be established. The developed system hinges on a successive calculation of the minimum value. Each of these minimum types can be put in relation to the measured energy consumption, however, depending on the chosen basis, the conclusion and focus of the calculated key figure may vary. By using the material minimum as a basis, the actually existing energy savings become visible. The method will be put to test through an exemplary application for processes in the fields of electronics production, electrical engineering, and production machining. This course of action allows the validation of the developed approach and reveals the potential of this method.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficiency; Energy efficiency validation; Manufacturing strategies; Production systems

EBenchmark-A pioneering method for process planning and sustainable manufacturing strategies for processes in the electric drives production - Kreitlein, Sven; Meyer, Alexander Wilhelm; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014, 2014)
This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production as well as corporate and cross-industry comparison. A directive for energy efficiency benchmarking has already been published, however, due to its lack of defined energy indicators, it does not allow for a significant comparison. In a preliminary step 120 currently used energy indicators were examined to assess their suitability as an energy benchmark. Based thereon, three approaches for the assessment of energy efficiency of the manufacturing processes in the production as well as a method for transferring the system by means of relevant indicators at the sectorial and corporate levels were developed. In the following, the approach of 'minimum value calculation', is presented in detail, which was identified as being most advantageous. The basic idea is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. Depending on the analysis of influencing factors, a model highlighting their dependencies could be established. The developed system hinges on a successive calculation of the minimum value. Each of these minimum types can be put in relation to the measured energy consumption, however, depending on the chosen basis, the conclusion and focus of the calculated key figure may vary. By using the material minimum as a basis, the actually existing energy savings become visible. The method will be put to the test through an exemplary application for processes in the fields of electronics production, electrical engineering, production machining and especially for processes in the electric drives production. This course of action allows for the validation of the developed approach and reveals the potential of this method.
Keywords: Energy Benchmark; Energy efficiency; Manufacturing strategy; Production

E|Benchmark - Approaches and methods for assessing the energy efficiency of the industrial automated product manufacturing - Kreitlein, Sven; Rackow, Tobias; Franke, Jörg (Applied Mechanics and Materials, 2014)
This paper introduces a method for the assessment and evaluation of energy efficiency of the manufacturing processes in the production as well as a corporate and cross-industry comparison. Already today, energy-related characteristic value systems are used, which are related to the energy consumption of large electronic household appliances or are focusing on their production facilities. The energy efficiency value is a newly developed indicator and will provide valuable information about the energy efficiency of the production of various products, production operators, and consumers. In the following, the energy efficiency value, which is based on the approach of minimal value calculation, is presented in detail. The basic idea is the comparison and evaluation of energy efficiency based on the ratio of the theoretically required energy consumption to the actual energy consumption. Depending on the analysis of influencing factors, a model highlighting their dependencies could be established. The developed system hinges on a successive calculation of the minimum value. Each of these minimum types can be put in relation to the measured energy consumption. However, depending on the chosen basis, the conclusion and focus of the calculated key figure may vary. By using the real minimum as a basis, the actually existing energy savings become visible. The method will be put to the test through an exemplary application for processes in the fields of cutting technologies. This course of action allows the validation of the developed energy efficiency value and reveals the potential of this method.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficiency; Energy efficiency validation; Manufacturing strategies

Echtzeitabbild der Produktion: Betriebsbegleitende Materialflusssimulation - Donhauser, Toni; Endter, Udo; Schmidt, Torben; Baier, Lukas; Schuderer, Peter; Franke, Jörg (wt Werkstattstechnik - Online, 2020)

Economic application of powder resin based groundwall insulation for low voltage electric drives - Hofmann, Benjamin; Kreitlein, Sven; Höcht, Matthias; Franke, Jörg (Annual Report - Conference on Electrical Insulation and Dielectric Phenomena, CEIDP, 2016)
Powder coating already forms an established variant of groundwall insulation although being used almost exclusively for small, flyer-wound rotors mostly due to the lack of economic application and curing processes for larger drives. However, insulation layers based on powder coatings are able to perform significantly better than common aramid-based slot liners. Regarding recent developments in powder application and curing, efficient application methods regarding energy consumption and process time are able to increase yield significantly. Regarding the altering topological characteristics of modern traction drives e.g. for electric vehicles, powder application and achievable results have to be investigated to assess the value of an industrial implementation. Experiments were performed using an electrostatic coating cell and a fixture simulating various characteristics of modern drives including inner diameter, slot width and -depth. These characteristics as well as available process values were analyzed towards the target figure coating thickness using DoE methods. Results predict a valid application of electrostatic powder coating within certain limits for larger traction drives. Package length should not exceed 80 mm and the diameter to package-length ratio has to be lower than 1.0 in order to achieve consistent, repeatable results. Electrostatic Powder Coating can be a valid alternative regarding groundwall insulation for traction drives, although the regarded process is expected to be best-suited for hybrid applications, due to large diameters and small package lengths of electric drives in this field.
CRIS-Team Scopus Importer:2023-03-07
Keywords: groundwall; insulation; powder coating

Economic Scheduling of Multi-Microgrid System Considering Power Grid Expansion Costs - Teske, Franz; Fehrle, Adrian; Funk, Felix; Franke, Jörg (2022)
With the proliferation of microgrids (MGs), power distribution grids are transforming into multi-microgrids (MMGs). In these systems, the focus is not only on the economic operation of the individual MGs but also on the power flows between the MGs and the superordinate grid. Therefore, for cost-efficient implementation of MMGs, not only the economic operation but also a cost-efficient design of the MMG must be ensured. Therefore, this paper proposes an approach to determine a cost-efficient MMG expansion that considers both investment and operating costs. Based on a model-based analysis it can be demonstrated that the overall system economics benefits when both components are considered in the scheduling of MGs. Through a series of simulations, it is also shown that the design can vary significantly due to different compositions of the MMG and variations in wholesale prices.<br
Keywords: Analytical models; Costs; Asia; Power distribution; Microgrids; Planning; Smart grids

Effect of Boundary Layer Tripping on the Aeroacoustics of Small Vertical Axis Wind Turbines - Weber, Johannes; Riedel, Sebastian; Praß, Julian; Renz, Andreas; Becker, Stefan; Franke, Jörg (Advanced Engineering Forum, 2016)

Effect of flow lines on the metallization of laser structured polymer parts - Fischer, Andreas; Kuhn, Thomas; Müller, Hagen; Drummer, Dietmar; Franke, Jörg; Zimmermann, Andre (SPE Proceedings Antec, 2017)

Effect of talc on the metal adhesion of laser-structured polymer parts - Fischer, Andreas; Kuhn, Thomas; Drummer, Dietmar; Franke, Jörg (13th International Congress Molded Interconnect Devices, 2018)

Efficient Method for Optimizing Calcium Silicate Masonry Unit Manufacturing Using Simulation-Based Optimization and Decomposition - Donhauser, Toni; Lohse, Joachim; Franke, Jörg; Schuderer, Peter (Energy Efficiency in Strategy of Sustainable Production Vol. II, 2017)
This paper describes an overall, simulation-based optimization approach to control plant operations for manufacturing calcium silicate masonry units (CS), which is directed towards and thus immediately applicable to practical processes. Starting from an investigation and classification of the CS production in order to differentiate the properties of each sub-process, specific target criteria are derived. To enable the influencing of these targets, relevant parameters including their mutual interdependencies are identified. On this basis, the criticality of each process step is assessed in order to determine improvement potentials and to investigate possible adjustments to the parameters.The elementary production types indicate a mix of the discontinuous and continuous processing in CS plants. Particularly, this work shows that through interrupting the continuous material flow, the hardening process is the main criteria for a plant’s success in meeting its targets, especially concerning energy efficiency. To achieve a feasible approach, the work develops a solving method geared to an optimized hardening process.Therefore, a formulation of a measureable target system is established, which is the prerequisite for modeling the whole optimization problem. An expedient decomposition of this optimization model to smaller sub-problems provides an efficient solving of these complex job-scheduling problems, in order to direct the method towards an operative use. The paper concludes with the determination of potential solving procedures for the overall problem and appropriate algorithms for solving the sub-problems.
Keywords: Decomposition; Job Shop; Scheduling; Simulation; Batch Processing; Target System; Operations Research; Optimization; Algorithm; Calcium Silicate Masonry Units; Flow Production

Efficient near Net-Shape Production of High Energy Rare Earth Magnets by Laser Beam Melting - Urban, Nikolaus; Meyer, Alexander Wilhelm; Kreitlein, Sven; Leicht, Felix; Franke, Jörg (Applied Mechanics and Materials, 2017)
Keywords: E|DRIVE

Efficient Semantic Mapping in Dynamic Environments - Hofmann, Christian; Fichtner, Mathias; Lieret, Markus; Franke, Jörg (PROCEEDINGS OF THE 17TH INTERNATIONAL JOINT CONFERENCE ON COMPUTER VISION, IMAGING AND COMPUTER GRAPHICS THEORY AND APPLICATIONS (VISAPP), VOL 4, 2022)
CRIS-Team WoS Importer:2022-05-06

Effiziente KI-Adaption durch synthetische Daten/Efficient AI Adaption using Synthetic Data - Blank, Andreas; Baier, Lukas; Kedilioglu, Oguz; Zhu, Xuebei; Metzner, Maximilian; Franke, Jörg (wt Werkstattstechnik - Online, 2021)
Production is characterized by an antagonism between flexibility and productivity. Deep Learning-based autonomous robot skills for object manipulation offer potential to solve existing challenges. Currently, the effort to generate appropriate datasets to adapt new components is time-consuming. In this research context, we present and evaluate a method for time-efficient data generation for object recognition based on synthetic data. Die Produktion ist geprägt durch einen Antagonismus aus Flexibilität und Produktivität. Objektmanipulation gestützt durch Deep-Learning-basierte, autonome Roboterfähigkeiten bietet Potenzial, bestehende Herausforderungen zu lösen. Der Aufwand zur Erzeugung zweckmäßiger Daten ist allerdings hoch. Im Beitrag vorgestellt und bewertet wird eine Methode zur zeiteffizienten Datengenerierung für die Objekterkennung mittels synthetischer Daten.<br
Keywords: Object Recognition; Machine Learning; Synthetic Data; AI Adaption; Annotation

Effizientes Engineering - Durchgängiger Simulationseinsatz in der Entwicklung von Sondermaschinen - Lechler, Tobias; Hocke, Gerald; Geier, Jennifer; Sitz, Sarah; Reinhard, Maximilian; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2020)

E|Flow - Decentralized Computer Architecture and Simulation Models for Sustainable and Resource Efficient Intralogistics - Scholz, Michael; Kreitlein, Sven; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production Vol. II, 2017)
Nowadays material flow in factories is realized by different concepts of transport. Each of those specific conveyers has pros and cons due to its concept. In general, the state of art of transport systems have a low flexibility of the path planning and are not suitable for dynamic transport requirements, wherefore they are designed for a specific application. Generally, the common systems cover a specific task of transportation and can fulfill a predefined maximum amount of transportation orders. Due to the effects of mass-customization there is an increase of the variance of the products combined with a reduction of the number of units per variation and a volatile costumer demand. Therefore, it is necessary that the next generations of production lines, especially the intralogistics transportation systems, have to be designed more adaptable and flexible. The object of the research in this paper is a cyber-physical material flow system with flexible, autonomous and collaborative vehicles combined with centralized sensors to digitalize the workspace. Furthermore, the number of vehicles in the system can be adjusted to the volume of the transport requirement, wherefore the system is suitable for different tasks in the intralogistics. Due to the approach of a decentralized digitalization of the workspace on the one hand side and the decentralized architecture of the path planning and order allocation system on the other hand side the concept lead to a nearly endless scalability of the system. The scalability is only restricted by the maximum number of entities which can use the communication system. Therefore, it is possible that the system adjust itself to the actual intralogistics demand as well as the dimension of the field of operation. This lead to a self-adjustable intralogistics transportation system which avoid a physical redesign of the whole system if the intralogistics demand is changing. To validate the approach, the decentralized intelligence of the transport entities and the production units is implemented in a discrete event simulation. In this simulation environment different task allocation methods, sizes of the transportation fleet, lot size management concepts and site layout concepts can be compared and rated which each other.
Keywords: Production Concepts; Decentralized Computer Architecture; Autonomous and Smart; Transportation Entities

E|Flow - From Production Line Concept to a Physically and Digitally Full-Meshed Production Network - Scholz, Michael; Hußnätter, Mona; Kreitlein, Sven; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production, 2015)
The continuous change of the consumers’ behavior combined with the impact of new technologies to the shop-floor is a challenge for the classic and established line production. Due to the effects of mass-customization there is an increase of the variants of the products combined with a reduction of the number of units per variation. Therefore, it is necessary that the next generations of production lines, especially the assembling devices, have to be designed more adaptable. Regarding to business information systems this trend is realized by a progressive digital integration of the particular units. However, at the physical level of the value stream the sequenced units are linked to each other and arranged flow-orientated since Taylor. Particularly, for mass production the so called “line concept” is well established. This inflexibility of the physical material flow blocks the spread of mass-customization into established industrial sectors where linked manufacturing steps are common use. A product which is very individualized is not, or only with an additional expense, producible on such linked lines. Therefore, it is necessary to resolve the linking of the physical material flow similar to the digital integration of the work flow. The result will be a physically and digitally full-meshed network of production units with a high variability. Especially for a production of goods with a high variant diversity the benefits of a physically meshed production site are obvious. Each part gets its own and individual routing, which depends on the current machine availability, the set-up and other factors. Furthermore, a change of the general conditions during the manufacturing of the part can be considered and lead to an adaption of the routing. One of the most important parts of a flexible physical production network is the transport system, consisting of autonomous and smart entities which are interconnected with business information systems, products and machines.
Keywords: Production Concepts; Physically and digitally Full-meshed Network; Autonomous and Smart Transportation Entities

E|Flow II - Infrastructural Sensor Concepts to Digitize the Workspace for Sustainable and Resource Efficient Intralogistics - Scholz, Michael; Venkataraman Ramasubramanian, Sudharshana; Blank, Andreas; Kreitlein, Sven; Franke, Jörg (Energy Efficiency in Strategy of Sustainable Production III, 2017)

Ein Ansatz zu Qualitätsvorhersage mittels intelligenter SMT-Lötstelleninspektion durch den Einsatz von Maschinellem Lernen - Schmidt, Konstantin; Bönig, Jochen; Beitinger, Gunter; Thielen, Nils; Franke, Jörg (GMM-Fb. 94: EBL 2020 – Elektronische Baugruppen und Leiterplatten, 2020)
The success factors of modern, global competition are changing the framework conditions of industrial production in a sustainable way. The optimization of the manufacturing process of electronic assemblies must ensure that they meet the requirements for adapted strategies and new design concepts, in particular in the field of digitization. Due to the already low error rates, which are achieved by highly optimized manufacturing and testing processes, future process improve-ments must be realized by reducing non-value-adding processes without endangering error rates. This can be reached through the targeted evaluation of recorded operating and machine data and the use of machine learning procedures. Due to the high standardization of processes and advanced plant networking, electronics manufacturing offers high application potential for data-driven process optimization. The state of the art often provides for cost- and time-intensive X-ray in-spection of hidden solder joints. According to the literature, the majority of solder joint defects are already caused by solder paste printing. This article therefore describes an approach for using the inspection data of the solder paste inspec-tion for quality prediction of the X-ray process. For the training of the model, the optical measurements are used as characteristics, together with the corresponding quality labels of the X-ray inspection, to establish a relationship between the solder paste printing and the quality result of the X-ray inspection for a selected product. The results were evaluated on the basis of various metrics and analysed for transferability into practice.<br
Keywords: Machine Learning; SMT; Manufacturing; X-Ray

Einfluss der Beschichtungssequenz auf die Bauteiltemperatur während eines plasmabasierten Kupferbeschichtungsprozesses auf unterschiedlichen Substratmaterialien - Hensel, Alexander; Müller, Martin; Franke, Jörg (EBL 2018 : multifunktionale Aufbau- und Verbindungstechnik - Beherrschung der Vielfalt : Vorträge der 9. DVS/GMM-Tagung in Fellbach am 20. und 21. Februar 2018, 2018)

Einfluss von Poren in Lötverbindungen bei LED-Anwendungen - Rauer, Miriam; Xu, Ping; Reinhardt, Andreas; Kaloudis, Michael; Franke, Jörg (Elektronische Baugruppen und Leiterplatten - EBL, 2016)
A high-quality joint between LED and substrate is mandatory to take advantage of the whole value creation potential of LEDs and to avoid premature failures. In the course of this investigations the influence of voids in solder joints on the thermal, electrical and thermo-mechanical reliability on the application of high power LEDs are determined. For this purpose test assemblies with high and low voiding levels were produced and characterized by use of conventional X-ray inspection and computer tomography. The benefit of the non-destructive three-dimensional analysis of voids by means of CT, is that the exact void position and its volume are well-known and cracks are detectable. As part of this article the results of the active power cycle test are presented. Additionally to the experimental investigations finite element simu-lations should be performed to study specific void positions and sizes in detail.
Keywords: Bordnetze; E|P; LED; Lötverbindung; Poren; Simulation; Zuverlässigkeit

Einsatz der ereignisdiskreten Materialflusssimulation bei Methoden aus der kontinuierlichen Verbesserung im Produktionsumfeld: Erfolg und Auswirkungen der Speedweek 4.0 - Sitz, Sarah; Zerreis, Maximilian; Lechler, Tobias; Franke, Jörg (Simulation in Produktion und Logistik 2021, 2021)

Einsatz von gedruckten Sensoren zur Messung der Dehnung von Wälzlagern unter isolierten Randbedingungen - Halmos, Fabian; Jüttner, Michael; Bartz, Marcel; Ankenbrand, Markus; Häusler, Felix; Franke, Jörg; Wartzack, Sandro (WiGeP News, 2023)

Ein Werkstoff für künstliche Muskeln und weiche Sensoren - Reitelshöfer, Sebastian; Landgraf, Maximilian; Franke, Jörg (2017)

Electrical and mechanical characterization of medical grade silicones as dielectric layers in aerosol jet printed dielectric elastomers - Martin, Sina; Himmler, Marcus; Bruns, Arne; Reitelshöfer, Sebastian; Pham, Duc Huy Hoang; Schubert, Dirk W.; Franke, Jörg (Proceedings Volume 11587, Electroactive Polymer Actuators and Devices (EAPAD) XXIII, 2021)
The name artificial muscles has given dielectric elastomer actuators much attention in the field of medical technology. In healthcare applications, these compliant materials are particularly suitable for soft and lightweight actuators and in addition, they show many advantageous properties such as great extensibility for on-body sensors. However, the lack of industrial scaled production capabilities is still a limiting factor in the transfer of these promising materials into a broad application. To address this issue, we have modified an aerosol jet printer for automated stacking of electrodes and dielectric layers in one process device, which is described in earlier publications. As the performance is mainly dependent on the electrical and mechanical characteristics of the dielectric, a broad material variety is required to face different tasks in healthcare technology. Therefore, different medical grade silicones are investigated in this paper regarding the suitability for aerosol jet printing. In a first step, the printing parameters are derived from rheological testing of the uncured components that are used pure and in mixture with silicone oils to vary the specific Young’s module. Through heat application and dilution, the range for printable materials increases to silicones with initial viscosities up to 8200 mPas. Subsequently aerosol jet printing is used to manufacture stacked silicone dielectrics that are then investigated regarding their mechanical and electrical characteristics for dielectric elastomers. Finally, the collected parameters are compared and an overview of the feasible property combinations is given which can be used as a material guideline for different applications.<br
Keywords: dielectric elastomers; medical grade silicones; mechanical characterization; electrical testing; additive manufacturing; rheological measurement; aerosol jet printing

Electrical and mechanical investigations on copper circuit paths coated on fiber-reinforced plastics by atmospheric plasma technology - Schramm, René; Reitberger, Thomas; Franke, Jörg (Journal of Microelectronics and Electronic Packaging, 2015)
Keywords: Additive metallization; Atmospheric plasma coating; Characterization; Plastics

Electrical and Mechanical Qualification of Selectively Dispensed Active Brazes - Stoll, Thomas; Franke, Jörg (2018 13th International Congress Molded Interconnect Devices (MID), 2018)

Electrical Characterization of Fibre-Reinforced Plastics by Atmospheric Plasma Technology - Schramm, René; Reitberger, Thomas; Franke, Jörg (2014)

Electrical functionalization of thermoplastic materials by cold active atmospheric plasma technology - Schramm, René; Franke, Jörg (Proceedings of the 2013 IEEE 15th Electronics Packaging Technology Conference, EPTC 2013, 2013)
Plasmadust® is a new technology using cold active plasma for additive metallization of different substrate materials. For electronics production, in particular Molded Interconnect Devices (MID), thermoplastic materials can be structured with copper as power electronic conductive pattern. The main advantages of Plasmadust® are the controllable process temperature range between about 90°C and 180°C, the good adhesion of the metallization, the fast process speed of about 100 mm/s and the fast growing conductor tracks with about 15 microns thickness per cycle. Plate specimens were made of PA, a thermoplastic commonly used in automotive applications, with different process parameters. Conductor tracks applied onto the substrates consist of one line with different electrical and mechanical properties according to the process temperature and process speed. Additionally, the thickness and the width of the conductor track depend on the process parameters. The setting of the process speed turns out to be an important influence on the thickness and roughness of the conductor track that can be achieved on thermoplastic substrates. The investigated combination of thermoplastic and copper shows a constant bonding performance during thermal shock testing for 1000 cycles in the range of-40°C and +125 °C. An exposure to humidity heat (85 % r.h / 85°C) for 500 h has only marginal effects on the adhesion of the printed structures on the thermoplastic substrates, too. This highly promising results provide the base for further investigations to achieve a sufficient ampacity related to standard chemical PCB metallization processes. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07

Electrical functionalization of thermoplastics by combining plasmadust coating and aerosol jet printing - Schramm, René; Hörber, Johannes; Dold, Christoph; Franke, Jörg (Advanced Materials Research, 2014)
Additive structuring and metallization technologies like Plasmadust or Aerosol Jet printing offer many advantages for future MID applications. Both digital writing technologies enable a highly flexible design of the circuit pattern and are capable of coating 3D substrates. Currently, Aerosol Jet printing is used to generate patterns with accurate and detailed features, and line widths of 100 μm. Plasmadust provides variable coating thicknesses up to 200 μm combined with a high process speed. Hence, a combination of both technologies appears to be advantageous for a broad range of MID applications. In this paper an initial study on the interconnection of plasmadust and Aerosol Jet generated conductive structures on thermoplastic substrate materials is presented. In this context different printing strategies and process variations are evaluated.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Additive metallization; Aerosol jet; Plasmadust; Structuring

Electric Motor Production 4.0 – Application Potentials of Industry 4.0 Technologies in the Manufacturing of Electric Motors - Mayr, Andreas; Weigelt, Michael; von Lindenfels, Johannes; Seefried, Johannes; Ziegler, Marco; Mahr, Alexander; Urban, Nikolaus; Kühl, Alexander; Hüttel, Franziska; Franke, Jörg (8th International Electric Drives Production Conference (EDPC), 2018)

Electric Propulsion Units in aviation - approach for a mechanical permanent magnet rotor design and the related manufacturing concept - von Lindenfels, Johannes; Ihne, Thorsten; Franke, Jörg; Kühl, Alexander (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
Electric propulsion units are key components for hybridization and electrification of aviation enabling decarbonization and emission reduction. This application is characterized by significant requirements regarding reliability and power density. This paper deals with a specific mechanical rotor design for Electric Propulsion Units configured as Halbach array and its related manufacturing process. First, existing rotor configurations of electric propulsion units are discussed. Based on this analysis optimization potentials regarding air gap minimization, cooling and retaining of centrifugal forces are introduced. The derived reference design compromises a modular setup of the magnetic active part including combinations of form fit and adhesive bond for all relevant interfaces. The individual advantages and disadvantages of the design as well as further optimization potentials are evaluated based on simulative and experimental investigations. The selected design correlates with a specific assembling and magnetization process which is also discussed. Due to a high number of single parts the assembling is performed as multistage process. The magnetization is conducted applying a sub-assembly strategy to avoid manufacturing problems. Finally, an outlook is given with focus set on the aviation compliant certification process.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric motor production; Electric Propulsion Units; Halbach Array; sub-assembly magnetization

Electromagnetic Actuators Suitable for High Temperatures Using Thin Aluminum Foil as Conductor - von Lindenfels, Johannes; Qomi, Mohammad Pahlevani; Utsch, Daniel; Franke, Jörg; Kühl, Alexander; Reibenweber, Lukas; Stadler, Alexander (2022 12th International Electric Drives Production Conference, EDPC 2022 - Proceedings, 2022)
Electromagnets are widely used as drive elements in many technical areas, e.g. as control elements for valves. The technical requirements include, for example, static and dynamic electromagnetic properties, compact design and reliability. On the economic side, the total costs must be considered. Copper (Cu) is predominantly used as a conductor material for electromagnets. However, this is problematic due to the fluctuating market prices of the metal. For example, the raw material prices for Cu have doubled somewhat between 2016 and 2022. In this paper, as an alternative to coils made of round Cu wire, options are sought for producing coils from anodised aluminum (AI) foil. For this purpose, the advantages and disadvantages of round Cu wire and Al foil are discussed with regard to material properties, manufacturing processes and handling. First, technical concepts for the realisation of this replacement are reported. Then the cylindrical coil is manufactured from anodised Al coil and a prototype of a cylindrical coil is built for demonstration. The newly manufactured coils are tested against the conventional coils made of Cu and the results of the comparison are presented.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Al2O3; aluminum foil; anodized aluminum; filling factor; solenoid; winding technology

Electronic module assembly - Franke, Jörg; Wang, Lihui; Bock, Karlheinz; Wilde, Juergen (CIRP Annals - Manufacturing Technology, 2021)
Electronics is the vital basis for innovations and the essential enabler for global trends like connectivity, electro mobility and renewable energies. These applications require high performance and reliability of the electronic modules. Their assembly combines very heterogeneous process chains like remarkable productive and diminutive surface mount technology (SMT), powerful and robust power electronic interconnection techniques, as well as pioneering reel-to-reel based organic electronic printing. After briefly outlining the enormous global economic impact of electronic modules, this paper presents the state of the art of electronic module assembly including substrate materials, electronic components, packaging and assembly processes as well as quality and reliability testing methods.
CRIS-Team Scopus Importer:2021-09-10
Keywords: Assembly; Electronic; Joining

Elektrische Speicherheizungen als Instrument zur elektrischen Lastverschiebung - Bürner, Johannes; Franke, Jörg (HLH, Heizung Lueftung/Klima Haustechnik, 2016)
Keywords: DSM; Speicherheizung; E|Home

Elektroband rotationsschneiden - Hubert, Markus; Franke, Jörg; Hackert, Jürgen (Draht, 2016)
Wo konventionelles Stanzen sich der hohen bewegten Massen wegen physikalischen Grenzen nähert, ist Rotationsschneiden erfolgreich. Vorliegender Beitrag arbeitet die Unterschiede zwischen den beiden Verfahren beim Verarbeiten von Elektroband heraus.

Elektromotorenproduktion 4.0: Potenziale des maschinellen Lernens in der Elektromotorenproduktion am Beispiel des Laserschweißens von Hairpins - Mayr, Andreas; Lutz, Benjamin; Weigelt, Michael; Gläßel, Tobias; Seefried, Johannes; Kißkalt, Dominik; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2019)

Enabling deep learning using synthetic data: A case study for the automotive wiring harness manufacturing - Nguyen, Huong Giang; Habiboglu, Resul; Franke, Jörg (Procedia CIRP, 2022)
The wiring harness manufacturing follows a high-variant manufacturing philosophy with a high degree of manual labor to produce customized products. Therefore, the process step of optical inspection is crucial to monitor, assess, and proactively safeguard the quality of produced wiring harnesses. To automate the optical inspection, which is currently manually conducted by operators, deep learning has become a powerful algorithm outperforming traditional computer vision approaches. Deep learning-based automated optical inspection systems can robustly and reliably detect rigid and deformable components, such as connectors, clips, single wires, and wire bundles. However, the bottleneck for scalable deep learning solutions in the industrial environment and high deep learning model performance is the database for model training and optimization. To address this research gap, we propose a deep learning-based data processing pipeline for automated optical inspection of wiring harnesses using real and synthetically generated point clouds. This paper outlines the process of real and synthetic data generation and evaluates the potential of synthetic data to enrich real data for model training. The data processing pipeline is implemented and experimental findings are generated to deduct important parameters for synthetic data generation and deep learning model training which impact model performance.<br
Keywords: Wiring Harness; Deep learning; Point clouds; Synthetic data; Domain gap

Enabling Live Data Controlled Manual Assembly Processes by Worker Information System and Nearfield Localization System - Fischer, Christian; Lusic, Mario; Faltus, Florian; Hornfeck, Rüdiger; Franke, Jörg (Procedia CIRP, 2016)
Abstract Existing localization solutions cannot be directly integrated into production systems. This article describes a nearfield localization system which can be installed on tools due to its small dimensions. Live data controlled manual assembly processes are enabled. In combination with worker information systems, the manual assembly process can be supported more precisely compared to common systems. The benefits are shown within product-specific assembly scenarios. One benefit is enabling work out of sight (non-visible range) guided through a virtual model on a screen. Error prevention (zero-defect assembly) can be realized by monitoring and matching the actual position to the assembly location. Even without augmented reality devices, comparative 3-D representations of real and virtual world are feasible, supporting employees in mobile workshop with complex repairs. In particular, difficult accessibility can be easily determined when carrying out maintenance work by knowing the complete product structure.
Keywords: Assembly; Information; Worker information system; Nearfield localization

Energetic Simulation of Complex Mechatronic Drive Systems over Complete Drive Cycles - Hörlin, Sebastian; Dietz, Armin; Hubert, Markus; Franke, Jörg (Applied Mechanics and Materials, 2015)
This paper presents a simulation model, which enables the energetic simulation of complex mechatronic powertrains over complete drive cycles. One focus of this work is on reducing the simulation duration to enable the simulation of extended drive cycles on the one hand, and the possibility to optimize drive cycles on the other hand. Furthermore, the program allows the user to assemble an energetically optimized selection of propulsion components.

Energieeffiziente Raumbelüftung mit Wärmerückgewinnung unter Verwendung eines neuartigen Wirkprinzips - Praß, Julian; Bürner, Johannes; Franke, Jörg (Umwelt-Technologie und Energie in Bayern, 2018)

Energieprognose mittels Methods-Energy Measurement - Berücksichtigung des Energiebedarfs in der frühen Planungsphase durch komponentenbasierte Energieplanung - Bornschlegl, Martin; Bregulla, Markus; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Eine frühzeitige Berücksichtigung des Energieverbrauchs im Planungsprozess ist sowohl ökologisch als auch ökonomisch sinnvoll. Dazu sind allerdings aussagekräftige Daten nötig, welche zu diesem Zeitpunkt oftmals noch nicht bereit stehen. Aus diesem Grund wurde der Methods-Energy Measurement-Ansatz konzipiert, damit eine ganzheitliche energetische Betrachtung der Fertigungsanlage über ihren Lebenszyklus im Planungsprozess erfolgen kann.
Keywords: Energieplanung

Energieprognose mittels Methods-Energy Measurement: Berücksichtigung des Energiebedarfs in der frühen Planungsphase durch komponentenbasierte Energieplanung - Bornschlegl, Martin; Bregulla, Markus; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
The reduction of energy costs of manufacturing technologies is both an important and current objective for factory operators. To achieve an estimation of the energy consumption in an early planning stage, a suitable forecast approach is required. This article shows how the prospective energy consumption can be determined by using Methods-Energy Measurement. This method contributes to identify and realize sustainable solutions in advance and as a result, increases the profitability of a factory.
CRIS-Team Scopus Importer:2023-03-07

Energieverbräuche in der Kosten- und Leistungsrechnung - Rackow, Tobias; Götz, Johannes; Schuderer, Peter; Franke, Jörg (Zeitschrift für wirtschaftlichen Fabrikbetrieb, 2015)
Especially in price sensitive and energy intensive sectors, rising energy costs lead to a differentiated handling of companies with their energy demands. Supported by energy management systems, companies gain more and more transparency over their energy consumptions. This article describes how this transparency can be utilized within the field of cost accounting, in order to evaluate the economic efficiency of the produced products.
CRIS-Team Scopus Importer:2023-03-07

Energy consumption and dynamic behavior analysis of a six-axis industrial robot in an assembly system - Paryanto, Paryanto; Brossog, Matthias; Kohl, Johannes; Merhof, Jochen; Spreng, Simon; Franke, Jörg (Procedia CIRP 23, 2014)
This paper presents an experimental study to validate a dynamic model of a six-axis industrial robot as part of an assembly system and to analyze its power consumption as well as its dynamic behavior. Furthermore, the effect of robot operating parameters (i.e., payload and speed) on the power consumption and the dynamic behavior are analyzed. The investigation shows that the comparative study between simulation and experimental results can be used to improve the model's accuracy and prove that the simulation model represents the real system. Both simulation and experimental results show that the robot operating parameters strongly influence the industrial robot's power consumption and dynamic behavio
Keywords: Energy simulation; Industrial Robot; Systems Engineering

Energy Consumption Modeling of a Turning Table and Standardized Integration into Virtual Commissioning - Hauf, Dominik; Kruck, Julian; Paryanto, Paryanto; Franke, Jörg (Procedia Manufacturing, 2017)
This paper describes the standardized integration of energy models into the virtual commissioning tool chain for a holistic energy consumption and peak power simulation of production cells used in the automotive industry. An energy model of a turning table as part of a demonstration cell is built in detail using modeling language Modelica. Further, an interface description for model connection to virtual commissioning is presented. Finally, simulation results are validated by measurements on a real demonstrator.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy efficency; functional mock-up interface (FMI); physics based modeling; sustainable manufacturing; virtual comissioning

Energy consumption modeling within the virtual commissioning tool chain - Hauf, D.; Meike, D.; Paryanto, Paryanto; Franke, Jörg (IEEE International Conference on Automation Science and Engineering, 2015)
In this paper an energy modeling approach within the virtual commissioning tool chain is presented. Virtual commissioning (VCom) today is a de facto methodology for programmable logic controller (PLC) software design and validation for automatic production systems. Energy consumption has never been an optimization criterion in VCom. Concepts of energy consumption modeling for any production unit have been investigated for measuring, visualization and optimization of control strategies. The hardware-in-the-loop simulation includes logical behavior models, the respective energy models and 3D-kinematic models of the production units, which are connected over common industrial bus network with a hardware-PLC. The concept has been developed for use with commercially available software tools so that the research results are implementation-oriented. An example from the automotive industry has been used.
CRIS-Team Scopus Importer:2023-03-07

Energy controlling - Analysis and evaluation of energy measuring equipment for the purpose of energy transparency in production plants - Rackow, Tobias; Javied, Tallal; Geith, Teresa; Schuderer, Peter; Franke, Jörg (Applied Mechanics and Materials, 2014)
This paper addresses the analysis and evaluation of energy measuring devices for the operation in the manufacturing industry. The focus lies on the comparison and scoring of energy meters regarding their performance spectrum against the backdrop of an energy controlling. Based on the fundamentals of electro technical metrology, the main measurement parameters were identified which are necessary for the purpose in the manufacturing industry. Further, capability characteristics for the differentiation of electricity meters were defined. With this, a classification of meters into a basic, a standard, an advanced and a premium class was undertaken. It is shown, that the advanced class is sufficient for the permanent monitoring of electricity consumption in the lights of energy controlling.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy controlling; Energy efficiency; Energy measuring equipment

Energy efficiency investigation on high-pressure convection reflow soldering in electronics production - Esfandyari, Alireza; Syed Khaja, Aarief Hussain; Javied, Tallal; Franke, Jörg (Trans Tech Publications Ltd, 2014)
One of the key factors in efficient and defect-free electronics manufacturing is the soldering of electronic components to the printed circuit boards. The deciding factor in the reliability and lifetime of the product is the quality of the soldered interconnections. The setting up of the reflow soldering profile plays a crucial role in the electrical functionality and robustness of the product. Especially the miniaturization of the assemblies and the development of new materials make it inevitable for the definition of new processes, optimization and implementation. In this paper, the combination of over-pressure and convection reflow soldering to minimize the defect rate and the related energy analysis for energy efficiency will be discussed and presented. An analysis with variations in solder time, cost, energy, quality trade-off in the over-pressure reflow soldering process for classical printed circuit boards (PCBs) has been demonstrated.
Keywords: Convection reflow soldering; Electronics production; Energy efficiency; Over-pressure

Energy efficient processes of electric motor manufacturing - Kühl, Alexander; Kreitlein, Sven; Höft, Annika; Franke, Jörg (2018 IEEE Texas Power and Energy Conference (TPEC), 2018)

Energy-efficient production strategies and technologies for electric drives - Franke, Jörg; Kreitlein, Sven; Risch, Florian; Günther, Stefan (Proceedings of the IEEE International Conference on Industrial Technology, 2013)
Due to the scarcity of resources the sustainable production of electric drives has become more and more important. In the context of a potentially huge increase in the demand for electric traction drives by the market of e-mobility, this topic is even more challenging. For this, new topologies with lower requirements for the needed valuable resources, new energy efficient drive concepts, optimized production, and logistic processes in terms of their resource requirements and integrated recycling strategies are presented in this paper. © 2013 IEEE.
CRIS-Team Scopus Importer:2023-03-07

Energy-efficient room ventilation with heat recovery using a novel concept - Praß, Julian; Bürner, Johannes; Franke, Jörg (Environment and Energy in Bavaria, 2018)

Energy flexible production: Saving electricity expenditures by adjusting the production plan - Rackow, Tobias; Kohl, Johannes; Canzaniello, A.; Schuderer, P.; Franke, Jörg (Procedia CIRP, 2015)
The energy turnaround in Germany increases the share of renewable energies. Since the amount of renewable energy supply is immanently subject of variation, the electricity price at the European Energy Exchange EEX is highly volatile. If companies would purchase the electricity directly at the EEX instead of from a wholesale power supplier along with price fixing, companies would benefit from increasing production in times with low electricity costs and reducing production in high-cost times. This paper shows, that influencing respectively shifting the time of electricity consumption -e.g. by adjustment of process parameter, shift period, order of jobs or machine utilization, by pausing of processes or delaying of job starts - can theoretically reduce electricity expenditures. The measures are being explained and discussed, followed by a description of company in-house and external requirements for the energy flexible production.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy expenditures; Energy flexibility; Energy management; Factory control; Flexible production

Energy KPI’s, challenges for sustainable manufacturing strategies, analysis of existing rules and indicators in an industrial environment in relation to the establishment of energy benchmark - Kreitlein, Sven; Rackow, Tobias; Franke, Jörg (Advanced Materials Research, 2014)
As this paper demonstrates, benchmarking is a powerful concept for increasing a company's success. It visualizes the differences in performance through internal or external indicators and is applied in almost all corporate divisions successfully. An important part of the benchmarking process is the selection of indicators that allow for a significant comparison. The requirements linked to the indicators are derived from the objectives of the specific benchmarking project. The use of benchmarking with respect to energy efficiency in product manufacturing promises a transparent presentation of performance differences and the possibility to derive optimization potentials - provided that appropriate energy figures can be found. The future challenge is to develop a system with standardized billing and key energy indicators that enable a cross-comparison of the energy efficiency in the production. This project is described in the research project E|Benchmark, part of the research network Green Factory Bavaria and funded by the Bavarian State Ministry for Science, Education and Arts.
CRIS-Team Scopus Importer:2023-03-07
Keywords: Energy benchmark; Energy efficiency; Production

Energy Planning of Manufacturing Systems with Methods-Energy Measurement (MEM) and Multi-Domain Simulation Approach - Bornschlegl, Martin; Paryanto, Paryanto; Spahr, Michael; Kreitlein, Sven; Bregulla, Markus; Franke, Jörg (Applied Mechanics and Materials, 2014)
Energy costs play a decisive role in the operation costs of automotive production companies. Therefore, energy planning in an early conception and planning stage becomes an important topic. This is because the early conception and planning stage has the greatest potential to influence the energy consumption of manufacturing technologies since about 70-80 % of the energy costs are committed during this stage. However, lifetime cost and specifically energy consumption are currently not a determining factor at this stage. The reason is that the prediction of energy costs for complex manufacturing systems are challenging. Previous research approaches in the area of energy planning are limited to detailed planned production. A standardized approach to determine the energy consumption rates at an early stage does not exist. In this context, the EffiPLAS project has therefore proposed to solve this challenge. The aim of this project is to develop a Methods-Energy Measurement approach with elementary energy elements to support the planning process at an early stage, and to develop a modular simulation model for calculating the energy consumption of industrial robots, which complements the energy prediction. In this paper, the basic concept of elementary energy units and their value determination techniques are presented, and the simulation model is outlined. The developed approach will help to predict the prospective energy consumption of complex production equipment so that energy costs can be accounted for in an improved manner within a life-cycle cost comparative analyses.
Keywords: Energy consumption; Energy efficiency; Energy simulation; Industrial robots; Methods-energy measurement (MEM); Production planning

Engineering von mechatronischen Baugruppen für die additive Fertigung - Zeitler, Jochen Tobias; Kühn, Cornelius; Urban, Nikolaus; Franke, Jörg (Konstruktion, 2017)
Als Reaktion auf den wachsenden Einfluss der Mechatronik auf die Industrie ist die additive Fertigung inzwischen so weit entwickelt, dass sie dazu in der Lage ist, die Bedürfnisse von räumlichen, hochintegrierten und interdisziplinären Baugruppen zu erfüllen. In Form eines hybriden, rein additiven Fertigungsprozesses können sowohl mechanische Substratkörper, elektrisch leitfähige Strukturen, sowie Inlets, die während des Fertigungsprozesses integriert werden, in einem einzigen Prozess zu einer Baugruppe kombiniert werden. Um diesen neuartigen Engineeringprozess zu unterstützen, werden innovative Ansätze und Werkzeuge der Konstruktionsmethodik vorgestellt.
Keywords: 3D-Druck; Konstruktion; Produktentwicklung; MID; CAD; Elektronik; Mechatronik

Enhanced Organizational Ambidexterity in Electronics Manufacturing through the Automation of Production-Related Processes - Bogner, Eva; Kästle, Christopher; Franke, Jörg (Proceedings of the 6th International Conference on Industrial Engineering and Operations Management, 2016)
The current discussion about the industrial Internet of Things (IoT) focuses in particular on diverse technologies and their possible applications in companies. However, the actual potential benefits and objectives of the fourth industrial revolution for companies are often neglected. The challenges posed by the increasing number of variants and decreasing batch sizes up to batch size one require special adaptability and flexibility. The aim is not only to offer customized products, but also to produce them with the efficiency of a mass production. This affects numerous business sectors. Whereas in the past the search for efficiency potentials was focused on the production process, it is now essential to consider strategic and operational corporate areas beyond production – the so-called overhead processes. The required flexibility of companies to produce mass-customized goods leads to an increased complexity of internal processes and a high proportion of additional overhead activities for the management of resources. In this paper, we provide an approach to automate repetitive, non-creative activities in all value added processes and to connect overhead processes with the production so that a fast, automated response to unplanned events in production is facilitated. Hence, an economical production can be realized in the context of mass customization.
Keywords: Industrial internet; Automation; Efficiency potentials; Potential benefits; Value-added processes; Electronics manufacturing

Enhanced X-Ray Inspection of Solder Joints in SMT Electronics Production using Convolutional Neural Networks - Schmidt, Konstantin; Thielen, Nils; Voigt, Christian; Seidel, Reinhardt; Franke, Jörg; Milde, Yannik; Bonig, Jochen; Beitinger, Gunter (2020 IEEE 26th International Symposium for Design and Technology in Electronic Packaging (SIITME), 2020)
The electronics production is prone to a multitude of possible failures along the production process. Therefore, the manufacturing process of surface-mounted electronics devices (SMD) includes visual quality inspection processes for defect detection. The detection of certain error patterns like solder voids and head in pillow defects require radioscopic inspection. These high-end inspection machines, like the X-ray inspection, rely on static checking routines, programmed manually by the expert user of the machine, to verify the quality. The utilization of the implicit knowledge of domain expert(s), based on soldering guidelines, allows the evaluation of the quality. The distinctive dependence on the individual qualification significantly influences false call rates of the inbuilt computer vision routines. In this contribution, we present a novel framework for the automatic solder joint classification based on Convolutional Neural Networks (CNN), flexibly reclassifying insufficient X-ray inspection results. We utilize existing deep learning network architectures for a region of interest detection on 2D grayscale images. The comparison with product-related meta-data ensures the presence of relevant areas and results in a subsequent classification based on a CNN. Subsequent data augmentation ensures sufficient input features. The results indicate a significant reduction of the false call rate compared to commercial X-ray machines, combined with reduced product-related optimization iterations.<br
Keywords: Inspection; Training; Soldering; X-ray imaging; Production; Image classification; Object detection; electronics production; automated X-ray inspection; machine learning; computervision; Convolutional Neural Networks

Enhancing Flexibility in Power Electronics Production: A Study on Robotic Handling of Copper Clips for Laser Bonding - Ockel, Manuela; Janisch, Lucas; Franke, Jörg; Schlichting, Johannes; Breuer, Marius (11th International Conference on Control, Mechatronics and Automation, ICCMA 2023, 2023)
Keywords: semiconductor device packaging; power electronics; robotics; laser bonding; gripper

Enhancing Men’s Health Management at Home with an Easy-to-Use, App-Connected Prostate Self-Testing Device - Benke, Elisabeth; Gschaidmeier, Simone; Gentsch, Olivier; Deittert, Hannes; Martin, Sina; Preis, Alexander; Franke, Jörg (Proceedings of the 16th International Joint Conference on Biomedical Engineering Systems and Technologies BIOSTEC, 2023)
A fundamental problem in men's health is that large groups of men shy away from visiting the doctor, and specifically, often do not take part in early screening tests if they do not have complaints yet. This is particularly evident in the sensitive field of urology. Benign prostatic hyperplasia (BPH) is one of the most widespread disorders in ageing men and is associated with an increasing burden on healthcare systems. It is often underdiagnosed and undertreated and has a substantial impact on the patients’ quality of life. An altered urine flow curve can be a first clue to BPH. A new developed, easy-to-use prostate self-testing device based on a Swiss high-precision flowmeter enables men to check their urine flow at home in familiar surroundings. Via a Bluetooth connection, the results can be transmitted wirelessly and stored in a digital diary so that longterm developments can be tracked. The self-testing device not only provides men with the opportunity to deal with their health with low effort and in a discreet way, but also gives them certainty about their prostate health status.
Keywords: Urology; Uroflowmetry; Benign Prostatic Hyperplasia; Prostate Conditions; Men’s Health

Entstörungsstrategie für autonome mobile Roboter Intervention strategy for autonomous mobile robots - Blank, Andreas; Berg, Julia; Zikeli, Georg Lukas; Lu, Shuang; Sommer, Oliver; Reinhart, Gunther; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Die Produktion ist geprägt durch einen Antagonismus aus Flexibilität und Produktivität. Autonome Roboter mit maschinell erlernten Fähigkeiten weisen Potenzial auf, das Spannungsfeld zu entlasten. Allerdings bedarf es aufgrund von Fehleranfälligkeit solcher Systeme Strategien zur Entstörung. Im Beitrag vorgestellt werden Methoden für die Vorortunterstützung mittels Werkerführung sowie zur Entstörung aus der Ferne mittels Teleoperation. Production is characterized by an antagonism between flexibility and productivity. Autonomous robots with learned skills show potential for relieving existing challenges. However, present failure susceptibility requires efficient intervention strategies to allow a technology establishment. This paper presents methods for on-site support based on a factory worker guidance system as well as remote assistance through teleoperatio
Keywords: Automatisierung; Industrieroboter; Mensch und Technik; Teleoperation

Entstörungsstrategie für autonome mobile Roboter/Intervention strategy for autonomous mobile robots - Blank, Andreas; Berg, Julia; Zikeli, Georg Lukas; Lu, Shuang; Sommer, Oliver; Reinhart, Gunther; Franke, Jörg (wt Werkstattstechnik - Online, 2020)
Production is characterized by an antagonism between flexibi-lity and productivity. Autonomous robots with learned skills show potential for relieving existing challenges. However, pre-sent failure susceptibility requires efficient intervention strate-gies to allow a technology establishment. This paper presents methods for on-site support based on a factory worker guidan-ce system as well as remote assistance through tele-operation.
CRIS-Team Scopus Importer:2021-04-19

Entwicklung einer Methodik zur ressourcenorientierten Steuerung der Werksprozesse in der Kalksandstein-Industrie: "KS-Sim" - Donhauser, Toni; Eden, Wolfgang; Franke, Jörg; Jung, Tobias; Schuderer, Peter (2015)

Entwicklung und Erprobung einer kosten- und funktionsoptimierten, mechatronischen Unterarmprothese - Yoo, In Seong; Scheithauer, Ellen Corinna; Sesselmann, Stefan; Franke, Jörg (3. Transdisziplinäre Konferenz – Technische Unterstützungssysteme, die die Menschen wirklich wollen, 2018)

Entwicklung und Evaluierung eines Systems zur automatisierten Prüfung von im Plasmabeschichtungsprozess additiv gefertigten Leiterbahnstrukturen für elektronische Baugruppen - Hahn, Dorothea; Braun, Thomas; Franke, Jörg (Elektronische Baugruppen und Leiterplatten EBL 2018, Multifunktionale Aufbau- und Verbindungstechnik – Beherrschung der Vielfalt, 2018)

Environment representation and path planning for unmanned aircraft in industrial indoor applications - Lieret, Markus; Kalenberg, Matthias; Hofmann, Christian; Franke, Jörg (FAIM 2021, 2021)
CRIS-Team WoS Importer:2022-10-28

Erkenntnisse aus der Biegesimulation von Flachdraht - Weigelt, Michael; Fröschl, Christian; Masuch, Michael; Riedel, Andreas; Franke, Jörg (Draht, 2018)
<span style="background-color: transparent; color: rgb(102, 102, 102); font-family: Georgia, "Times New Roman", serif; font-size: 14px; font-style: italic; font-variant-numeric: normal; font-variant-east-asian: normal; line-height: 20px;">Dank einer simultanen Entwicklung aus struktur-mechanischer FE-Simulation und Versuchserkenntnissen lassen sich Formspulen von Traktionsmotoren kosten- und zeiteffizienter gestalten und innerhalb eines definierten Prozessfensters fertigen.

Erzeugung von 3D-Funktionsstrukturen fuer Hochfrequenzanwendungen durch Druckverfahren - Ankenbrand, Markus; Franke, Jörg; Lomakin, Konstantin; Pavlenko, Tatiana; Sippel, Mark; Gold, Gerald; Weidner, T; Weiß, D; Helmreich, Klaus (PLUS - Produktion von Leiterplatten und Systemen, 2018)

Evaluating thermoset resin substrates for 3D mechatronic integrated devices and packaging - Häußler, Felix; Shen, Shengxia; Petillon, Simon; Weser, Sascha; Haybat, Mehmet; Eberhardt, Wolfgang; Zimmermann, André; Franke, Jörg (International Symposium on Microelectronics, 2020)
Miniaturization efforts and increasing demands regarding reliability of mechatronic systems require new materials and processes for the 3D mechatronic integrated devices (3D-MID) technology. Currently, in the area of 3D-MID mostly thermoplastic materials are in use in the industry, which are metallized using the LPKF-LDS® process. This paper is supposed to demonstrate the eligibility of thermoset resins as a new material class for 3D-MID applications and as a packaging option for silicon chips which are currently encapsulated using transfer molding of thermosets. The reliability of the conductor tracks made using a LDS-additive free process as well as the adhesion forces are investigated. Different laser parameters for structuring of two different substrate materials are compared. For reliability testing a thermal shock test is applied. Furthermore, the adhesion is tested using Hot-Pin-Pull testing. The conductor tracks surpass 2000 cycles thermo-mechanical load without showing strong deterioration of the track resistivity. The incorporated approach enables electrically reliable functionalization of packaged dummy chips including vias for connection to terminals on the chips. The results of the tested injection moldable thermoset resins are comparable to state-of-the-art 3D-MID thermoplastic substrates and thus, suited as circuit carrier material in electronic packaging.<br

Evaluation and Assessment of Additive Manufacturing Processes Based on the Least Energy Demand in Application for Sustainable Production - Kreitlein, Sven; Urban, Nikolaus; Gerter, Viktor; Franke, Jörg (Applied Mechanics and Materials, 2017)

Evaluation and Characterization of 3D Printed Pyramid Horn Antennas utilizing different Deposition Techniques for Conductive Material - Lomakin, Konstantin; Pavlenko, Tatiana; Ankenbrand, Markus; Sippel, Mark; Ringel, Johannes; Scheetz, Matthias; Klemm, Tobias; Gräf, Daniel; Helmreich, Klaus; Franke, Jörg; Gold, Gerald (IEEE Transactions on Components, Packaging and Manufacturing Technology, 2018)
This paper evaluates different metal deposition approaches for a two-staged additive manufacturing (AM) process for 3-D horn antennas, divided into the deposition of plastic and conductive material. The demonstrated fabrication workflow allows for antennas of low cost and low weight and, therefore, demonstrates the vast benefit of AM. The comparison of a commercially available cast aluminum horn to the fabricated prototypes reveals a deviation of up to 3 dB in terms of transmission losses in copolarization over a distance of 1.85 m. Cross-polarization measurements are presented revealing a larger variation among the different metallization approaches. The results shown in this paper demonstrate a successful application of AM in radio frequency engineering. Moreover, one of the presented approaches makes use of only 3-D printing systems and is, therefore, potentially suitable for totally automated manufacturin
lhft_intern.bib::Lomakin2018g

Evaluation der virtuellen Absicherung hybrider Montagesysteme mittels Kinematik- und Ergonomiesimulationswerkzeugen - Metzner, Maximilian; Heinlein, Pascal; Wytopil, Benedict; Donhauser, Toni; Franke, Jörg (ASIM 2019, 2019)

Evaluation of an algorithm for optical pulse detection in children for application to the Pepper robot - Goes, Nina; Kirst, Simone; Seßner, Julian; Steffan, Jan; Struck, Matthias; Franke, Jörg; Naumann, S.; Dziobek, I.; Lang, Nadine; Wittenberg, Thomas (Current Directions in Biomedical Engineering, 2021)
To engage in socio-emotional interactions, children with autism spectrum conditions (ASC) need support to understand and convey emotions. In our approach, a humanoid robot (Pepper, Softbanks Robotics) acts as a tutor for the child within autism care. The robot, equipped with multimodal sensor technology to acquire the emotional feedback of the child, stimulates the child to perform tasks, adapted to its current arousal state. By in-, or decreasing the difficulties of implemented training modules, the child can be given the appropriate task according to its emotional state. The child's arousal is measured with different techniques implemented in and on the robot: emotion detection based on audio recordings of the speech signal and camera detected facial expressions, or heart rate. To this end, the remote Photoplethysmography (rPPG) signal from camera recordings of the subjects' face is acquired. While its unintrusive measurement is an advantage, a major drawback for rPPG is its proneness to motion and light artefacts requiring de-noising steps. A wavelet transform based on log-Gabor wavelets and a filter bank with 32 filters was implemented. The signal was filtered with a prior filter and afterwards with a Markov chain in order to extract the underlying pulse rate. Within an initial study, five children were observed watching videos with different co-notated emotions. As reference for the heart rate (HR), a wristband (empatica E4) was used. The captured emotions of all subjects were annotated to identify low and high arousal parts and positive and negative emotions. Extracted HR from rPPG-data indicated a correlation with the annotated emotions.
CRIS-Team Scopus Importer:2023-03-07
Keywords: autistic children; optical pulse assessment; rPPG; social robotics

Evaluation of deep learning for semantic image segmentation in tool condition monitoring - Lutz, Benjamin; Kißkalt, Dominik; Regulin, Daniel; Reisch, Raven; Schiffler, Andreas; Franke, Jörg (2019 18th IEEE International Conference On Machine Learning And Applications (ICMLA), 2019)

Evaluation of detatchable board-to-board interconnects on screen printed electronic structures - Schirmer, Julian; Huemmer, Michael; Klauss, Matthias; Neermann, Simone; Reichenberger, Marcus; Franke, Jörg (Flexible and Printed Electronics, 2021)
Hybrid printed electronics (HPE) combines advantages of conventional electronics manufacturing technologies such as surface mount technology with those of printed electronics in order to realize more complex electronic systems. To realize the final product, such HPE subassemblies have to be connected to higher-level assemblies. So far interconnection techniques for the so-called level 3 interconnection between printed subsystems and standard electronics have not yet been considered adequately in scientific research. In this paper, alternative detachable level 3 interconnection technologies, i.e. spring loaded contact pins, zero insertion force (ZIF) as well as Non-ZIF connectors are investigated systematically regarding their electrical behaviour against the background of printed electronics. Screen-printed silver filled polymer thick film paste is used to realize printed conductor patterns on flexible polymer substrates, which are connected later on with the alternatives mentioned above. Transition resistance is measured using the four wire method as produced, after repeated mating cycles as well as after accelerated aging tests. The various electrical contacts are subjected to thermal stress in temperature cycling testing and during aging at a constant high temperature. As a result it can be stated, that the sping-loaded contact pins used in this investigation show superior behavior compared with the selected connectors in terms of resistance increase after mating cycles. Concerning long-term behavior after thermal cyling and high temperature storage, all investigated alternaives reveal convincing results.
CRIS-Team WoS Importer:2021-09-24

Evaluation of different methods for removing the conductor insulation of stranded conductors - Riedel, Andreas; Hahn, Roman; Kühl, Alexander; Franke, Jörg (12th International Symposium on Advanced Topics in Electrical Engineering, ATEE 2021, 2021)
The ecological change in society and politics leads to an increased demand for alternative drives. In the field of mobility, this can be observed by ongoing innovations in research and development as well as in the production of electric machines. Currently, the automotive industry is focusing more and more on traction drives using hairpin technology. The reasons for this are the easier automation of the manufacturing process and the higher copper filling factors that can be achieved. The latter help to improve the power density. At high frequencies, which inevitably occur in high-speed applications, large conductor dimensions lead to additional losses due to eddy currents. To reduce these losses, twisted round wires can be used instead of flat conductors. Nevertheless, the manufacturing as well as the processing of this semi-finished product is more complex. The aim of this paper is to present and compare the possibilities for removing the required tape of the stranded conductor and to substantiate it with initial results. For this purpose, the general production chain of a hairpin stator is explained at the beginning of the paper in order to show the reasons why the removal of the bandage is of elementary importance. This is supplemented by technological aspects of stranded wire technology which cause-effect relationships serve as the basis for the main part of this paper.
CRIS-Team Scopus Importer:2021-06-11
Keywords: Electric traction drives; Hairpin winding; Insulation material; Litz wire; Skinning methods; Stranded conductors

Evaluation of economic and ecologic potential of induction heating in the context of insulation systems within electric drives - Hofmann, Benjamin; Spreng, Simon; Kühl, Alexander; Franke, Jörg (IEEE Electrical Insulation Conference, 2015)
Resin applications have always been found within the production of electric drives. Replacing natural materials like tar and rubber, industrial produced polymers quickly spread amongst all major components and manufacturing steps of electric machines. Today, thermosetting resins are mainly used within the disciplines of insulation and fixation of materials, manifesting in wire enamels, impregnation varnishes, potting resins and thermally curing adhesives. Numerous variations in topology create various challenges around these products. Thermal curing generally uses an excessive amount of energy when being conducted by oven heating or infrared radiation. Alternative and particularly energy-efficient technologies are available, but have yet to be investigated from a scientific perspective. Within the research project E vertical bar Solation, the E vertical bar Drive-Center at the institute FAPS of the Friedrich-Alexander-University of Erlangen-Nuernberg has aimed to investigate induction heating technology as an energy-saving method for thermosetting resin and powder coat curing to create insulating layers within an automated and flexible production of electric drives. Saving potential in the context of electrical sheet laminations has shown to be as high as up to 95% of electrical energy. In order to determine the value of this technology, simulative as well as empiric investigations have to be made to create a better understanding of how induction heating of sheet lamination works and to determine feasibility and integration into current production processes. The paper will present the latest outcomes of energy-focused value stream methods in order to determine applicable scenarios and production thresholds, in which induction heating can be a viable alternative to current heating technologies. In parallel, a simulative approach is under development to determine temperature distribution during heating process of laminated cores. The project aims for an extensive and fundamental knowledge of the process itself in order to determine optimal heating times and maximum efficiency.
Keywords: insulation; resin; induction heating

Evaluation of energy efficient joining processes in the field of electric drives manufacturing considering quality aspects - Spreng, Simon; Risch, Florian; Glabel, Tobias; Wolff, Josse; Franke, Jörg (2014 4th International Electric Drives Production Conference, EDPC 2014 - Proceedings, 2014)
The implementation of green products and matching manufacturing processes increasingly attract public attention. Therefore, the institute FAPS analyzed the joining process as it is identified to be one of the major energy consumers in the context of electric drives manufacturing. The present approach introduces a statistically developed methodology to predict the energy consumption and the resulting connection quality of one of the major, currently available joining techniques. Therefore an analytical model was developed, which was afterwards used to optimize the parameter settings of an industrial cooperation partner.
CRIS-Team Scopus Importer:2023-03-07
Keywords: electric drives manufacturing; energy consumption; joining; thermo crimping

Evaluation of energy measurements for error detection in press-fitting processes - Sand, Christian; Meiners, Moritz; Eberle, Jonathan; Franke, Jörg (2018 2nd International Symposium on Small-Scale Intelligent Manufacturing Systems, SIMS 2018, 2018)
Modern assembly lines consist of many different stations like assembly presses, which are rigidly chained or stand-alone on the shop floor. Current state-of-the-art process monitoring regards force-way curves to classify good or defective process runs using tolerance windows or envelop curves. Yet, approaches for online monitoring based on energy data are hardly used in assembly presses. Therefore, avoidable failure and scrap costs, as well as resource and material waste occur due to commonly unobserved malicious process states. This paper evaluates which types of errors can be detected and if an energy-based process observation is a useful addition or alternative to conventional process monitoring. Here, relevant information is used to generate deeper insight into assembly processes. Impacts like altered material, different batches of supply parts, tool wear and tool breakage shall be revealed by utilizing electrical current curves. Therefore, assembly settings are varied by six impact factors to evaluate their significance on force-displacement-curves. Eventually, a methodology on how to detect and compare key points in characteristic curves is proposed when evaluating energy data acquisition with current-displacement-curves thus presenting possible prospective research topics on deeper data analysis with data mining methods.
CRIS-Team Scopus Importer:2023-03-07
Keywords: current-displacement-curve; DoE; Force-displacement-curve; press-fit connection

Evaluation of energy measurements for error detection in press-fitting processes - Sand, Christian; Meiners, Moritz; Eberle, Jonathan; Franke, Jörg (Small-scale Intelligent Manufacturing Systems (SIMS), 2018 2nd International Symposium on, 2018)