@inproceedings{BagheriSchleupenDahmannetal.2016, author = {Bagheri, Mohsen and Schleupen, Josef and Dahmann, Peter and Kallweit, Stephan}, title = {Kletternde Wartungsplattform f{\"u}r die wetterunabh{\"a}ngige Instandhaltung von Rotorbl{\"a}ttern an Windenergieanlagen - SMART}, series = {AKIDA 2016 Aachener Kolloquium f{\"u}r Instandhaltung, Diagnose und Anlagen{\"u}berwachung (AKIDA) am 15. und 16.11.2016, Technologiezentrum Aachen}, booktitle = {AKIDA 2016 Aachener Kolloquium f{\"u}r Instandhaltung, Diagnose und Anlagen{\"u}berwachung (AKIDA) am 15. und 16.11.2016, Technologiezentrum Aachen}, pages = {21 Folien}, year = {2016}, abstract = {In Deutschland liegt der Anteil der Windkraft an der Gesamtstromerzeugung bei 13,3\% mit mehr als 25.000 installierten Windenergieanlagen (WEA). Weltweit erf{\"a}hrt die Windbranche ein rasantes Wachstum. Indien und China berichten eine j{\"a}hrliche Wachstumsrate an Neuinstallationen von 45\%. Die Technologie zur Erzeugung elektrischer Energie aus Windkraft ist noch vergleichsweise jung. Durch die weltweit steigende Anzahl an Windenergieanlagen w{\"a}chst zunehmend der Bedarf an innovativen Wartungsl{\"o}sungen. Komponenten wie Generator oder Getriebe sind inzwischen weitestgehend ausgereift. Der Fokus richtet sich zunehmend auf die wesentliche Kernkomponente - die Rotorbl{\"a}tter. Industriekletterer inspizieren die Rotorbl{\"a}tter oder T{\"u}rme i.d.R. in einem zwei Jahres Rhythmus. Sie werden zunehmend durch Seilarbeitsb{\"u}hnen unterst{\"u}tzt. F{\"u}r gr{\"o}ßere Reparaturen kommen Kr{\"a}ne zum Einsatz, mit denen das Rotorblatt f{\"u}r die Instandhaltung demontiert wird. Die Standardinspektion besteht aus Sicht- und Klopfpr{\"u}fung der Rotorblattoberfl{\"a}che und ist nur bei sehr ruhiger Wetterlage durchf{\"u}hrbar. Seit September 2014 wird das Forschungsprojekt SMART (Scanning, Monitoring, Analysis, Repair and Transportation), Entwicklung einer Wartungsplattform f{\"u}r WEA, vom BMWi gef{\"o}rdert. Das Konsortium besteht aus zwei Firmen und der Fachhochschule Aachen. Die SMART-Anlage klettert reibschl{\"u}ssig am Turm der WEA mittels speziellen Kettenfahrwerken (Abbildung) auf- und abw{\"a}rts. Ein ringf{\"o}rmiges Spannsystems, basierend auf dem Konzept der „N{\"u}rnberger"-Schere, erzeugt die erforderliche Anpresskraft f{\"u}r den Kletterprozess. Wettergesch{\"u}tzte Arbeitskabinen erm{\"o}glichen die ganzj{\"a}hrige Instandhaltung von Rotorbl{\"a}ttern und ebenso T{\"u}rmen. Dadurch k{\"o}nnen Wartungsarbeiten auf 24 Stunden am Tag ausgeweitet werden. Der kombinierte Einsatz (Sensorfusion) bildgebender Messtechnik wie Thermografie, Ultraschall, und Terahertz in der Arbeitskabine kann die Dokumentation, Effizienz und Qualit{\"a}t der Instandhaltungsarbeiten erheblich verbessern. Langfristiges Ziel von SMART ist ein Condition Monitoring f{\"u}r Rotorbl{\"a}tter und T{\"u}rme auf Basis digitalisierter dreidimensionaler Volumenscans. Der kooperative Einsatz mit UAVs erweitert die Instandhaltungsstrategie. UAVs erm{\"o}glichen die schnelle, kosteng{\"u}nstige globale optische Inspektion von Rotorblattoberfl{\"a}chen zur Detektion potentieller Fehlstellen. Der „Proof-of-Concept" Meilenstein wurde mit der Demonstration eines funktionsf{\"a}higen Modells im Dezember 2015 erfolgreich abgeschlossen.}, language = {de} } @article{MichauxMatternKallweit2018, author = {Michaux, F. and Mattern, P. and Kallweit, Stephan}, title = {RoboPIV: how robotics enable PIV on a large industrial scale}, series = {Measurement Science and Technology}, volume = {29}, journal = {Measurement Science and Technology}, number = {7}, publisher = {IOP}, address = {Bristol}, issn = {1361-6501}, doi = {10.1088/1361-6501/aab5c1}, pages = {074009}, year = {2018}, abstract = {This work demonstrates how the interaction between particle image velocimetry (PIV) and robotics can massively increase measurement efficiency. The interdisciplinary approach is shown using the complex example of an automated, large scale, industrial environment: a typical automotive wind tunnel application. Both the high degree of flexibility in choosing the measurement region and the complete automation of stereo PIV measurements are presented. The setup consists of a combination of three robots, individually used as a 6D traversing unit for the laser illumination system as well as for each of the two cameras. Synchronised movements in the same reference frame are realised through a master-slave setup with a single interface to the user. By integrating the interface into the standard wind tunnel management system, a single measurement plane or a predefined sequence of several planes can be requested through a single trigger event, providing the resulting vector fields within minutes. In this paper, a brief overview on the demands of large scale industrial PIV and the existing solutions is given. Afterwards, the concept of RoboPIV is introduced as a new approach. In a first step, the usability of a selection of commercially available robot arms is analysed. The challenges of pose uncertainty and importance of absolute accuracy are demonstrated through comparative measurements, explaining the individual pros and cons of the analysed systems. Subsequently, the advantage of integrating RoboPIV directly into the existing wind tunnel management system is shown on basis of a typical measurement sequence. In a final step, a practical measurement procedure, including post-processing, is given by using real data and results. Ultimately, the benefits of high automation are demonstrated, leading to a drastic reduction in necessary measurement time compared to non-automated systems, thus massively increasing the efficiency of PIV measurements.}, language = {en} } @article{KunkelGebhardtMpofuetal.2018, author = {Kunkel, Maximilian Hugo and Gebhardt, Andreas and Mpofu, Khumbaulani and Kallweit, Stephan}, title = {Statistical assessment of mechanical properties of selective laser melted specimens of stainless steel}, series = {The International Journal of Advanced Manufacturing Technology}, volume = {98}, journal = {The International Journal of Advanced Manufacturing Technology}, number = {5-8}, publisher = {Springer}, address = {London}, issn = {0268-3768}, doi = {10.1007/s00170-018-2040-8}, pages = {1409 -- 1431}, year = {2018}, abstract = {The rail business is challenged by long product life cycles and a broad spectrum of assembly groups and single parts. When spare part obsolescence occurs, quick solutions are needed. A reproduction of obsolete parts is often connected to long waiting times and minimum lot quantities that need to be purchased and stored. Spare part storage is therefore challenged by growing stocks, bound capital and issues of part ageing. A possible solution could be a virtual storage of spare parts which will be 3D printed through additive manufacturing technologies in case of sudden demand. As mechanical properties of additive manufactured parts are neither guaranteed by machine manufacturers nor by service providers, the utilization of this relatively young technology is impeded and research is required to address these issues. This paper presents an examination of mechanical properties of specimens manufactured from stainless steel through the selective laser melting (SLM) process. The specimens were produced in multiple batches. This paper interrogates the question if the test results follow a normal distribution pattern and if mechanical property predictions can be made. The results will be put opposite existing threshold values provided as the industrial standard. Furthermore, probability predictions will be made in order to examine the potential of the SLM process to maintain state-of-the-art mechanical property requirements.}, language = {en} } @article{LimpertWiesenFerreinetal.2019, author = {Limpert, Nicolas and Wiesen, Patrick and Ferrein, Alexander and Kallweit, Stephan and Schiffer, Stefan}, title = {The ROSIN Project and its Outreach to South Africa}, series = {R\&D Journal}, volume = {35}, journal = {R\&D Journal}, pages = {1 -- 6}, year = {2019}, language = {en} } @inproceedings{KleineKallweitMichauxetal.2016, author = {Kleine, Harald and Kallweit, Stephan and Michaux, Frank and Havermann, Marc and Olivier, Herbert}, title = {PIV Measurement of Shock Wave Diffraction}, series = {18th International Symposium on Applications of Laser Techniques to Fluid Mechanics, 2016, Lissabon}, booktitle = {18th International Symposium on Applications of Laser Techniques to Fluid Mechanics, 2016, Lissabon}, pages = {1 -- 14}, year = {2016}, language = {en} } @inproceedings{SchleupenEngemannBagherietal.2016, author = {Schleupen, Josef and Engemann, Heiko and Bagheri, Mohsen and Kallweit, Stephan}, title = {The potential of SMART climbing robot combined with a weatherproof cabin for rotor blade maintenance}, series = {17th European Conference on Composite Materials - ECCM, Munich, Germany}, booktitle = {17th European Conference on Composite Materials - ECCM, Munich, Germany}, pages = {1 -- 8}, year = {2016}, language = {en} } @inproceedings{WiesenEngemannLimpertetal.2018, author = {Wiesen, Patrick and Engemann, Heiko and Limpert, Nicolas and Kallweit, Stephan}, title = {Learning by Doing - Mobile Robotics in the FH Aachen ROS Summer School}, series = {European Robotics Forum 2018, TRROS18 Workshop}, booktitle = {European Robotics Forum 2018, TRROS18 Workshop}, pages = {47 -- 58}, year = {2018}, language = {en} } @article{EngemannCoenenDawaretal.2021, author = {Engemann, Heiko and C{\"o}nen, Patrick and Dawar, Harshal and Du, Shengzhi and Kallweit, Stephan}, title = {A robot-assisted large-scale inspection of wind turbine blades in manufacturing using an autonomous mobile manipulator}, series = {Applied Sciences}, volume = {11}, journal = {Applied Sciences}, number = {19}, publisher = {MDPI}, address = {Basel}, issn = {2076-3417}, doi = {10.3390/app11199271}, pages = {1 -- 22}, year = {2021}, abstract = {Wind energy represents the dominant share of renewable energies. The rotor blades of a wind turbine are typically made from composite material, which withstands high forces during rotation. The huge dimensions of the rotor blades complicate the inspection processes in manufacturing. The automation of inspection processes has a great potential to increase the overall productivity and to create a consistent reliable database for each individual rotor blade. The focus of this paper is set on the process of rotor blade inspection automation by utilizing an autonomous mobile manipulator. The main innovations include a novel path planning strategy for zone-based navigation, which enables an intuitive right-hand or left-hand driving behavior in a shared human-robot workspace. In addition, we introduce a new method for surface orthogonal motion planning in connection with large-scale structures. An overall execution strategy controls the navigation and manipulation processes of the long-running inspection task. The implemented concepts are evaluated in simulation and applied in a real-use case including the tip of a rotor blade form.}, language = {en} } @inproceedings{EngemannWiesenKallweitetal.2018, author = {Engemann, Heiko and Wiesen, Patrick and Kallweit, Stephan and Deshpande, Harshavardhan and Schleupen, Josef}, title = {Autonomous mobile manipulation using ROS}, series = {Advances in Service and Industrial Robotics}, booktitle = {Advances in Service and Industrial Robotics}, publisher = {Springer}, address = {Cham}, isbn = {978-3-319-61276-8}, doi = {10.1007/978-3-319-61276-8_43}, pages = {389 -- 401}, year = {2018}, language = {en} } @inproceedings{EngemannBadriWenningetal.2019, author = {Engemann, Heiko and Badri, Sriram and Wenning, Marius and Kallweit, Stephan}, title = {Implementation of an Autonomous Tool Trolley in a Production Line}, series = {Advances in Service and Industrial Robotics. RAAD 2019. Advances in Intelligent Systems and Computing, vol 980}, booktitle = {Advances in Service and Industrial Robotics. RAAD 2019. Advances in Intelligent Systems and Computing, vol 980}, publisher = {Springer}, address = {Cham}, isbn = {978-3-030-19648-6}, doi = {10.1007/978-3-030-19648-6_14}, pages = {117 -- 125}, year = {2019}, language = {en} }