@inproceedings{PfaffMoshiriReichetal.2017, author = {Pfaff, Raphael and Moshiri, Amir and Reich, Alexander and G{\"a}bel, Markus}, title = {Modelling of the effect of sanding on the wheel-rail adhesion area}, series = {First International Conference on Rail Transportation}, booktitle = {First International Conference on Rail Transportation}, pages = {1 -- 7}, year = {2017}, language = {en} } @inproceedings{ShahidiPfaffEnning2017, author = {Shahidi, Parham and Pfaff, Raphael and Enning, Manfred}, title = {The connected wagon - a concept for the integration of vehicle side sensors and actors with cyber physical representation for condition based maintenance}, series = {First International Conference on Rail Transportation}, booktitle = {First International Conference on Rail Transportation}, pages = {1 -- 8}, year = {2017}, language = {en} } @inproceedings{PfaffShahidiEnning2017, author = {Pfaff, Raphael and Shahidi, Parham and Enning, Manfred}, title = {Connected freight rail rolling stock: a modular approach integrating sensors, actors and cyber physical systems for operational advantages and condition based maintenance}, series = {Asia-Pacific Conference of the Prognostics and Health Management Society}, booktitle = {Asia-Pacific Conference of the Prognostics and Health Management Society}, pages = {1 -- 7}, year = {2017}, language = {en} } @inproceedings{Pfaff2017, author = {Pfaff, Raphael}, title = {Analysis of Big Data Streams to obtain Braking Reliability Information for Train Protection systems}, series = {Asia-Pacific Conference of the Prognostics and Health Management Society}, booktitle = {Asia-Pacific Conference of the Prognostics and Health Management Society}, pages = {1 -- 7}, year = {2017}, language = {en} } @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} } @inproceedings{FerreinSchifferKallweit2018, author = {Ferrein, Alexander and Schiffer, Stefan and Kallweit, Stephan}, title = {The ROSIN Education Concept - Fostering ROS Industrial-Related Robotics Education in Europe}, series = {ROBOT 2017: Third Iberian Robotics Conference}, booktitle = {ROBOT 2017: Third Iberian Robotics Conference}, publisher = {Springer}, address = {Cham}, isbn = {978-3-319-70836-2}, doi = {10.1007/978-3-319-70836-2_31}, pages = {370 -- 381}, year = {2018}, language = {en} } @book{GebhardtKesslerThurn2019, author = {Gebhardt, Andreas and Kessler, Julia and Thurn, Laura}, title = {3D printing : understanding additive manufacturing}, edition = {2. Auflage}, publisher = {Hanser}, address = {M{\"u}nchen}, isbn = {978-1-56990-702-3}, pages = {XVI, 204 Seiten}, year = {2019}, language = {en} } @inproceedings{FateriGebhardtRenftle2015, author = {Fateri, Miranda and Gebhardt, Andreas and Renftle, Georg}, title = {Additive manufacturing of drainage segments for cooling system of crucible melting furnaces}, series = {Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials II, International Symposium on Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials, ICACC 15, 39th International Conference on Advanced Ceramics and Composites, Daytona Beach, FL, US, Jan 25-30, 2015}, booktitle = {Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials II, International Symposium on Advanced Processing and Manufacturing Technologies for Structural and Multifunctional Materials, ICACC 15, 39th International Conference on Advanced Ceramics and Composites, Daytona Beach, FL, US, Jan 25-30, 2015}, publisher = {Wiley}, address = {Hoboken}, issn = {0196-6219}, doi = {10.1002/9781119211662.ch14}, pages = {123 -- 131}, year = {2015}, language = {en} } @inproceedings{GaoBabilonPfaffetal.2018, author = {Gao, H. and Babilon, Katharina and Pfaff, Raphael and Gan, F. and Reich, A.}, title = {Model of wheel-rail contact for sanding and adhesion enhancement}, series = {Proceedings of the 11th International Conference on Contact Mechanics and Wear of Rail/wheel Systems, CM 2018}, booktitle = {Proceedings of the 11th International Conference on Contact Mechanics and Wear of Rail/wheel Systems, CM 2018}, isbn = {978-946186963-0}, pages = {314 -- 321}, year = {2018}, language = {en} } @article{FranzenPindersPfaffetal.2018, author = {Franzen, Julius and Pinders, Erik and Pfaff, Raphael and Enning, Manfred}, title = {RailCrowd's virtual fleets: Make most of your asset data}, series = {Deine Bahn}, journal = {Deine Bahn}, number = {9}, publisher = {Bahn-Fachverlag}, address = {Berlin}, issn = {0948-7263}, pages = {11 -- 13}, year = {2018}, abstract = {For smaller railway operators or those with a diverse fleet, it can be difficult to collect sufficient data to improve maintenance programs. At the same time, new rules such as entity in charge of maintenance - ECM - regulations impose an additional workload by requiring a dedicated maintenance management system and specific reports. The RailCrowd platform sets out to facilitate compliance with ECM and similar regulations while at the same time pooling anonymised fleet data across operators to form virtual fleets, providing greater data insights.}, language = {en} } @inproceedings{PfaffMelcherFranzen2018, author = {Pfaff, Raphael and Melcher, Karin and Franzen, Julian}, title = {Rare event simulation to optimise maintenance intervals of safety critical redundant subsystems}, series = {Proceedings of the European Conference of the PHM Society}, volume = {4}, booktitle = {Proceedings of the European Conference of the PHM Society}, number = {1}, pages = {1 -- 6}, year = {2018}, language = {en} } @inproceedings{ThurnGebhardt2018, author = {Thurn, Laura and Gebhardt, Andreas}, title = {Strategy of Education on Materials for Students}, series = {Conference Proceedings: „New Perspectives in Science Education"}, booktitle = {Conference Proceedings: „New Perspectives in Science Education"}, address = {Florence, Italy}, isbn = {978-88-6292-976-9}, pages = {156 -- 161}, year = {2018}, language = {en} } @inproceedings{BueckingPfaffDirksmeier2018, author = {B{\"u}cking, Henrik and Pfaff, Raphael and Dirksmeier, Roger}, title = {Sensor positioning and thermal model for condition monitoring of pressure gas reservoirs in vehicles}, series = {Proceedings of the Fourth European Conference of the Prognostics and Health Management Society, Utrecht, Netherlands, 2018}, booktitle = {Proceedings of the Fourth European Conference of the Prognostics and Health Management Society, Utrecht, Netherlands, 2018}, pages = {5 Seiten}, year = {2018}, 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} } @inproceedings{RieperGebhardtStucker2016, author = {Rieper, Harald and Gebhardt, Andreas and Stucker, Brent}, title = {Process parameters for Selective Laser Melting of AgCu7}, series = {DDMC, Fraunhofer Direct Digital Manufacturing Conference, 3}, booktitle = {DDMC, Fraunhofer Direct Digital Manufacturing Conference, 3}, publisher = {Fraunhofer-Verlag}, address = {Stuttgart}, isbn = {978-3-8396-1001-5}, pages = {171 -- 176}, year = {2016}, language = {en} } @incollection{FranzenSteckenPfaffetal.2019, author = {Franzen, Julian and Stecken, Jannis and Pfaff, Raphael and Kuhlenk{\"o}tter, Bernd}, title = {Using the Digital Shadow for a Prescriptive Optimization of Maintenance and Operation : The Locomotive in the Context of the Cyber-Physical System}, series = {Advances in Production, Logistics and Traffic}, booktitle = {Advances in Production, Logistics and Traffic}, publisher = {Springer}, address = {Cham}, isbn = {978-3-030-13535-5}, doi = {10.1007/978-3-030-13535-5_19}, pages = {265 -- 276}, year = {2019}, abstract = {In competition with other modes of transport, rail freight transport is looking for solutions to become more attractive. Short-term success can be achieved through the data-driven optimization of operations and maintenance as well as the application of novel strategies such as prescriptive maintenance. After introducing the concept of prescriptive maintenance, this paper aims to prove that vehicle-focused applications of this approach indeed have the potential to increase attractiveness. However, even greater advantages can be activated if data from the horizontal network of the vehicle is available. Drawing on the state of the art in research and technology in the field of cyber-physical systems (CPS) as well as digital twins and shadows, our work serves to design a system of systems for the horizontal interconnection of a rail vehicle and to conceptualize a draft for a digital twin of a locomotive.}, language = {en} } @article{BucurLazarescuPopetal.2019, author = {Bucur, Alexandru and Lazarescu, Lucian and Pop, Grigore Marian and Achimas, Gheorghe and Gebhardt, Andreas}, title = {Tribological performance of biodegradable lubricants under different surface roughness of tools}, series = {Academic Journal of Manufacturing Engineering}, volume = {17}, journal = {Academic Journal of Manufacturing Engineering}, number = {1}, issn = {1583-7904}, pages = {172 -- 178}, year = {2019}, language = {en} } @article{PancContiuBocanetetal.2019, author = {Panc, Nicolae and Contiu, Glad and Bocanet, Vlad and Thurn, Laura and Sabau, Emilia}, title = {The influence of cutting technology on surface wear hardness}, series = {Academic Journal of Manufacturing Engineering}, volume = {17}, journal = {Academic Journal of Manufacturing Engineering}, number = {3}, issn = {1583-7904}, pages = {205 -- 210}, year = {2019}, language = {en} } @inproceedings{LuftGebhardtBalc2019, author = {Luft, Angela and Gebhardt, Andreas and Balc, Nicolae}, title = {Challenges of additive manufacturing in production systems}, series = {Modern technologies in manufacturing (MTeM 2019)}, volume = {299}, booktitle = {Modern technologies in manufacturing (MTeM 2019)}, number = {Article 01003}, doi = {10.1051/matecconf/201929901003}, pages = {6 Seiten}, year = {2019}, language = {en} } @inproceedings{AbbasThurnKessleretal.2019, author = {Abbas, Karim and Thurn, Laura and Kessler, Julia and Eichler, Fabian}, title = {Basic research of the consideration of additive manufactured lattice structures under thermoand fluid dynamic loads}, series = {Modern technologies in manufacturing (MTeM 2019)}, volume = {299}, booktitle = {Modern technologies in manufacturing (MTeM 2019)}, number = {Article 01009}, doi = {10.1051/matecconf/201929901009}, pages = {8 Seiten}, year = {2019}, language = {en} } @inproceedings{EichlerSkupinThurnetal.2019, author = {Eichler, Fabian and Skupin, Marco and Thurn, Laura and Kasch, Susanne and Schmidt, Thomas}, title = {Operating limits for beam melting of glass materials}, series = {Modern Technologies in Manufacturing (MTeM 2019)}, volume = {299}, booktitle = {Modern Technologies in Manufacturing (MTeM 2019)}, number = {Article 01004}, doi = {10.1051/matecconf/201929901004}, pages = {8 Seiten}, year = {2019}, abstract = {Laser-based Additive Manufacturing (AM) processes for the use of metals out of the powder bed have been investigated profusely and are prevalent in industry. Although there is a broad field of application, Laser Powder Bed Fusion (LPBF), also known as Selective Laser Melting (SLM) of glass is not fully developed yet. The material properties of glass are significantly different from the investigated metallic material for LPBF so far. As such, the process cannot be transferred, and the parameter limits and the process sequence must be redefined for glass. Starting with the characterization of glass powders, a parameter field is initially confined to investigate the process parameter of different glass powder using LPBFprocess. A feasibility study is carried out to process borosilicate glass powder. The effects of process parameters on the dimensional accuracy of fabricated parts out of borosilicate and hints for the post-processing are analysed and presented in this paper.}, language = {en} } @article{UlmerBraunChengetal.2020, author = {Ulmer, Jessica and Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Human-Centered Gamification Framework for Manufacturing Systems}, series = {Procedia CIRP}, volume = {93}, journal = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2020.04.076}, pages = {670 -- 675}, year = {2020}, abstract = {While bringing new opportunities, the Industry 4.0 movement also imposes new challenges to the manufacturing industry and all its stakeholders. In this competitive environment, a skilled and engaged workforce is a key to success. Gamification can generate valuable feedbacks for improving employees' engagement and performance. Currently, Gamification in workspaces focuses on computer-based assignments and training, while tasks that require manual labor are rarely considered. This research provides an overview of Enterprise Gamification approaches and evaluates the challenges. Based on that, a skill-based Gamification framework for manual tasks is proposed, and a case study in the Industry 4.0 model factory is shown.}, language = {en} } @article{WollbrinkMasloZimmeretal.2020, author = {Wollbrink, Moritz and Maslo, Semir and Zimmer, Daniel and Abbas, Karim and Arntz, Kristian and Bergs, Thomas}, title = {Clamping and substrate plate system for continuous additive build-up and post-processing of metal parts}, series = {Procedia CIRP}, volume = {93}, journal = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2020.04.015}, pages = {108 -- 113}, year = {2020}, abstract = {The manufacturing share of laser powder bed fusion (L-PBF) increases in industrial application, but still many process steps are manually operated. Additionally, it is not possible to achieve tight dimensional tolerances or low surfaces roughness. Hence, a process chain has to be set up to combine additive manufacturing (AM) with further machining technologies. To achieve a continuous workpiece flow as basis for further industrialization of L-PBF, the paper presents a novel substrate system and its application on L-PBF machines and post-processing. The substrate system consists of a zero-point clamping system and a matrix-like interface of contact pins to be substantially connected to the workpiece within the L-PBF process.}, language = {en} } @article{FrankoDuKallweitetal.2020, author = {Franko, Josef and Du, Shengzhi and Kallweit, Stephan and Duelberg, Enno Sebastian and Engemann, Heiko}, title = {Design of a Multi-Robot System for Wind Turbine Maintenance}, series = {Energies}, volume = {13}, journal = {Energies}, number = {10}, publisher = {MDPI}, address = {Basel}, issn = {1996-1073}, doi = {10.3390/en13102552}, pages = {Article 2552}, year = {2020}, abstract = {The maintenance of wind turbines is of growing importance considering the transition to renewable energy. This paper presents a multi-robot-approach for automated wind turbine maintenance including a novel climbing robot. Currently, wind turbine maintenance remains a manual task, which is monotonous, dangerous, and also physically demanding due to the large scale of wind turbines. Technical climbers are required to work at significant heights, even in bad weather conditions. Furthermore, a skilled labor force with sufficient knowledge in repairing fiber composite material is rare. Autonomous mobile systems enable the digitization of the maintenance process. They can be designed for weather-independent operations. This work contributes to the development and experimental validation of a maintenance system consisting of multiple robotic platforms for a variety of tasks, such as wind turbine tower and rotor blade service. In this work, multicopters with vision and LiDAR sensors for global inspection are used to guide slower climbing robots. Light-weight magnetic climbers with surface contact were used to analyze structure parts with non-destructive inspection methods and to locally repair smaller defects. Localization was enabled by adapting odometry for conical-shaped surfaces considering additional navigation sensors. Magnets were suitable for steel towers to clamp onto the surface. A friction-based climbing ring robot (SMART— Scanning, Monitoring, Analyzing, Repair and Transportation) completed the set-up for higher payload. The maintenance period could be extended by using weather-proofed maintenance robots. The multi-robot-system was running the Robot Operating System (ROS). Additionally, first steps towards machine learning would enable maintenance staff to use pattern classification for fault diagnosis in order to operate safely from the ground in the future.}, language = {en} } @inproceedings{BraunChengDoweyetal.2020, author = {Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Survey on Security Concepts to Adapt Flexible Manufacturing and Operations Management based upon Multi-Agent Systems}, series = {2020 IEEE 29th International Symposium on Industrial Electronics (ISIE)}, booktitle = {2020 IEEE 29th International Symposium on Industrial Electronics (ISIE)}, doi = {10.1109/ISIE45063.2020.9152210}, year = {2020}, language = {en} } @article{RaffeisAdjeiKyeremehVroomenetal.2020, author = {Raffeis, Iris and Adjei-Kyeremeh, Frank and Vroomen, Uwe and Westhoff, Elmar and Bremen, Sebastian and Hohoi, Alexandru and B{\"u}hrig-Polaczek, Andreas}, title = {Qualification of a Ni-Cu alloy for the laser powder bed fusion process (LPBF): Its microstructure and mechanical properties}, series = {Applied Sciences}, volume = {10}, journal = {Applied Sciences}, number = {Art. 3401}, publisher = {MDPI}, address = {Basel}, issn = {2076-3417}, doi = {10.3390/app10103401}, pages = {1 -- 15}, year = {2020}, abstract = {As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni-Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of the Monel family of alloys with Nb and high Si content is, for the first time, processed via the laser powder bed fusion process (LPBF). Being novel to the LPBF processes, optimum LPBF parameters were determined, and hardness and tensile tests were performed in as-built conditions and after heat treatment at 1000 °C. Microstructures of the as-cast and the as-built condition were compared. Highly dense samples (99.8\% density) were achieved after varying hatch distance (80 µm and 140 µm) with scanning speed (550 mm/s-1500 mm/s). There was no significant difference in microhardness between varied hatch distance print sets. Microhardness of the as-built condition (247 HV0.2) exceeded the as-cast microhardness (179 HV0.2.). Tensile specimens built in vertical (V) and horizontal (H) orientations revealed degrees of anisotropy and were superior to conventionally reported figures. Post heat treatment increased ductility from 20\% to 31\% (V), as well as from 16\% to 25\% (H), while ultimate tensile strength (UTS) and yield strength (YS) were considerably reduced.}, language = {en} } @article{KunkelGebhardtMpofuetal.2019, author = {Kunkel, Maximilian Hugo and Gebhardt, Andreas and Mpofu, Khumbulani and Kallweit, Stephan}, title = {Quality assurance in metal powder bed fusion via deep-learning-based image classification}, series = {Rapid Prototyping Journal}, volume = {26}, journal = {Rapid Prototyping Journal}, number = {2}, issn = {1355-2546}, doi = {10.1108/RPJ-03-2019-0066}, pages = {259 -- 266}, year = {2019}, language = {en} } @inproceedings{UlmerBraunChengetal.2021, author = {Ulmer, Jessica and Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Adapting Augmented Reality Systems to the users' needs using Gamification and error solving methods}, series = {Procedia CIRP}, volume = {104}, booktitle = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2021.11.024}, pages = {140 -- 145}, year = {2021}, abstract = {Animations of virtual items in AR support systems are typically predefined and lack interactions with dynamic physical environments. AR applications rarely consider users' preferences and do not provide customized spontaneous support under unknown situations. This research focuses on developing adaptive, error-tolerant AR systems based on directed acyclic graphs and error resolving strategies. Using this approach, users will have more freedom of choice during AR supported work, which leads to more efficient workflows. Error correction methods based on CAD models and predefined process data create individual support possibilities. The framework is implemented in the Industry 4.0 model factory at FH Aachen.}, language = {en} } @article{BraunChengDoweyetal.2021, author = {Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Performance evaluation of skill-based order-assignment in production environments with multi-agent systems}, series = {IEEE Journal of Emerging and Selected Topics in Industrial Electronics}, journal = {IEEE Journal of Emerging and Selected Topics in Industrial Electronics}, number = {Early Access}, publisher = {IEEE}, address = {New York}, issn = {2687-9735}, doi = {10.1109/JESTIE.2021.3108524}, year = {2021}, abstract = {The fourth industrial revolution introduces disruptive technologies to production environments. One of these technologies are multi-agent systems (MASs), where agents virtualize machines. However, the agent's actual performances in production environments can hardly be estimated as most research has been focusing on isolated projects and specific scenarios. We address this gap by implementing a highly connected and configurable reference model with quantifiable key performance indicators (KPIs) for production scheduling and routing in single-piece workflows. Furthermore, we propose an algorithm to optimize the search of extrema in highly connected distributed systems. The benefits, limits, and drawbacks of MASs and their performances are evaluated extensively by event-based simulations against the introduced model, which acts as a benchmark. Even though the performance of the proposed MAS is, on average, slightly lower than the reference system, the increased flexibility allows it to find new solutions and deliver improved factory-planning outcomes. Our MAS shows an emerging behavior by using flexible production techniques to correct errors and compensate for bottlenecks. This increased flexibility offers substantial improvement potential. The general model in this paper allows the transfer of the results to estimate real systems or other models.}, language = {en} } @inproceedings{ChavezBermudezWollert2022, author = {Chavez Bermudez, Victor Francisco and Wollert, J{\"o}rg}, title = {10BASE-T1L industry 4.0 smart switch for field devices based on IO-Link}, series = {2022 IEEE 18th International Conference on Factory Communication Systems (WFCS)}, booktitle = {2022 IEEE 18th International Conference on Factory Communication Systems (WFCS)}, publisher = {IEEE}, isbn = {978-1-6654-1086-1}, doi = {10.1109/WFCS53837.2022.9779176}, pages = {4 Seiten}, year = {2022}, abstract = {The recent amendment to the Ethernet physical layer known as the IEEE 802.3cg specification, allows to connect devices up to a distance of one kilometer and delivers a maximum of 60 watts of power over a twisted pair of wires. This new standard, also known as 10BASE-TIL, promises to overcome the limits of current physical layers used for field devices and bring them a step closer to Ethernet-based applications. The main advantage of 10BASE- TIL is that it can deliver power and data over the same line over a long distance, where traditional solutions (e.g., CAN, IO-Link, HART) fall short and cannot match its 10 Mbps bandwidth. Due to its recentness, IOBASE- TIL is still not integrated into field devices and it has been less than two years since silicon manufacturers released the first Ethernet-PHY chips. In this paper, we present a design proposal on how field devices could be integrated into a IOBASE-TIL smart switch that allows plug-and-play connectivity for sensors and actuators and is compliant with the Industry 4.0 vision. Instead of presenting a new field-level protocol for this work, we have decided to adopt the IO-Link specification which already includes a plug-and-play approach with features such as diagnosis and device configuration. The main objective of this work is to explore how field devices could be integrated into 10BASE-TIL Ethernet, its adaption with a well-known protocol, and its integration with Industry 4.0 technologies.}, language = {en} } @inproceedings{UlmerBraunChengetal.2022, author = {Ulmer, Jessica and Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Usage of digital twins for gamification applications in manufacturing}, series = {Procedia CIRP}, volume = {107}, booktitle = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2022.05.044}, pages = {675 -- 680}, year = {2022}, abstract = {Gamification applications are on the rise in the manufacturing sector to customize working scenarios, offer user-specific feedback, and provide personalized learning offerings. Commonly, different sensors are integrated into work environments to track workers' actions. Game elements are selected according to the work task and users' preferences. However, implementing gamified workplaces remains challenging as different data sources must be established, evaluated, and connected. Developers often require information from several areas of the companies to offer meaningful gamification strategies for their employees. Moreover, work environments and the associated support systems are usually not flexible enough to adapt to personal needs. Digital twins are one primary possibility to create a uniform data approach that can provide semantic information to gamification applications. Frequently, several digital twins have to interact with each other to provide information about the workplace, the manufacturing process, and the knowledge of the employees. This research aims to create an overview of existing digital twin approaches for digital support systems and presents a concept to use digital twins for gamified support and training systems. The concept is based upon the Reference Architecture Industry 4.0 (RAMI 4.0) and includes information about the whole life cycle of the assets. It is applied to an existing gamified training system and evaluated in the Industry 4.0 model factory by an example of a handle mounting.}, language = {en} } @inproceedings{DannenSchindelePruemmeretal.2022, author = {Dannen, Tammo and Schindele, Benedikt and Pr{\"u}mmer, Marcel and Arntz, Kristian and Bergs, Thomas}, title = {Methodology for the self-optimizing determination of additive manufacturing process eligibility and optimization potentials in toolmaking}, series = {Procedia CIRP}, volume = {107}, booktitle = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2022.05.188}, pages = {1539 -- 1544}, year = {2022}, abstract = {Additive Manufacturing (AM) of metallic workpieces faces a continuously rising technological relevance and market size. Producing complex or highly strained unique workpieces is a significant field of application, making AM highly relevant for tool components. Its successful economic application requires systematic workpiece based decisions and optimizations. Considering geometric and technological requirements as well as the necessary post-processing makes deciding effortful and requires in-depth knowledge. As design is usually adjusted to established manufacturing, associated technological and strategic potentials are often neglected. To embed AM in a future proof industrial environment, software-based self-learning tools are necessary. Integrated into production planning, they enable companies to unlock the potentials of AM efficiently. This paper presents an appropriate methodology for the analysis of process-specific AM-eligibility and optimization potential, added up by concrete optimization proposals. For an integrated workpiece characterization, proven methods are enlarged by tooling-specific figures. The first stage of the approach specifies the model's initialization. A learning set of tooling components is described using the developed key figure system. Based on this, a set of applicable rules for workpiece-specific result determination is generated through clustering and expert evaluation. Within the following application stage, strategic orientation is quantified and workpieces of interest are described using the developed key figures. Subsequently, the retrieved information is used for automatically generating specific recommendations relying on the generated ruleset of stage one. Finally, actual experiences regarding the recommendations are gathered within stage three. Statistic learning transfers those to the generated ruleset leading to a continuously deepening knowledge base. This process enables a steady improvement in output quality.}, language = {en} } @inproceedings{KoenigWolf2016, author = {K{\"o}nig, Johannes Alexander and Wolf, Martin}, title = {A new definition of competence developing games - and a framework to assess them}, series = {ACHI 2016 : The Ninth International Conference on Advances in Computer-Human Interactions}, booktitle = {ACHI 2016 : The Ninth International Conference on Advances in Computer-Human Interactions}, isbn = {978-1-61208-468-8}, pages = {95 -- 97}, year = {2016}, abstract = {There are different types of games that try to make use of the motivation of a gaming situation in learning contexts. This paper introduces the new terminology 'Competence Developing Game' (CDG) as an umbrella term for all games with this intention. Based on this new terminology, an assessment framework has been developed and validated in scope of an empirical study. Now, all different types of CDGs can be evaluated according to a defined and uniform set of assessment criteria and, thus, are comparable according to their characteristics and effectiveness.}, language = {en} } @article{AbbasBalcBremenetal.2022, author = {Abbas, Karim and Balc, Nicolae and Bremen, Sebastian and Skupin, Marco}, title = {Crystallization and aging behavior of polyetheretherketone PEEK within rapid tooling and rubber molding}, series = {Journal of Manufacturing and Materials Processing}, volume = {6}, journal = {Journal of Manufacturing and Materials Processing}, number = {5}, publisher = {MDPI}, address = {Basel}, issn = {2504-4494}, doi = {10.3390/jmmp6050093}, pages = {1 -- 12}, year = {2022}, abstract = {In times of short product life cycles, additive manufacturing and rapid tooling are important methods to make tool development and manufacturing more efficient. High-performance polymers are the key to mold production for prototypes and small series. However, the high temperatures during vulcanization injection molding cause thermal aging and can impair service life. The extent to which the thermal stress over the entire process chain stresses the material and whether it leads to irreversible material aging is evaluated. To this end, a mold made of PEEK is fabricated using fused filament fabrication and examined for its potential application. The mold is heated to 200 ◦C, filled with rubber, and cured. A differential scanning calorimetry analysis of each process step illustrates the crystallization behavior and first indicates the material resistance. It shows distinct cold crystallization regions at a build chamber temperature of 90 ◦C. At an ambient temperature above Tg, crystallization of 30\% is achieved, and cold crystallization no longer occurs. Additional tensile tests show a decrease in tensile strength after ten days of thermal aging. The steady decrease in recrystallization temperature indicates degradation of the additives. However, the tensile tests reveal steady embrittlement of the material due to increasing crosslinking.}, language = {en} } @inproceedings{WeissHeslenfeldSaeweetal.2022, author = {Weiss, Christian and Heslenfeld, Jonas and Saewe, Jasmin Kathrin and Bremen, Sebastian and H{\"a}fner, Constantin Leon}, title = {Investigation on the influence of powder humidity in Laser Powder Bed Fusion (LPBF)}, series = {Procedia CIRP}, volume = {111}, booktitle = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2022.08.102}, pages = {115 -- 120}, year = {2022}, abstract = {In the Laser Powder Bed Fusion (LPBF) process, parts are built out of metal powder material by exposure of a laser beam. During handling operations of the powder material, several influencing factors can affect the properties of the powder material and therefore directly influence the processability during manufacturing. Contamination by moisture due to handling operations is one of the most critical aspects of powder quality. In order to investigate the influences of powder humidity on LPBF processing, four materials (AlSi10Mg, Ti6Al4V, 316L and IN718) are chosen for this study. The powder material is artificially humidified, subsequently characterized, manufactured into cubic samples in a miniaturized process chamber and analyzed for their relative density. The results indicate that the processability and reproducibility of parts made of AlSi10Mg and Ti6Al4V are susceptible to humidity, while IN718 and 316L are barely influenced.}, language = {en} } @incollection{FateriGebhardt2020, author = {Fateri, Miranda and Gebhardt, Andreas}, title = {Introduction to Additive Manufacturing}, series = {3D Printing of Optical Components}, booktitle = {3D Printing of Optical Components}, publisher = {Springer}, address = {Cham}, isbn = {978-3-030-58960-8}, doi = {10.1007/978-3-030-58960-8_1}, pages = {1 -- 22}, year = {2020}, abstract = {Additive manufacturing (AM) works by creating objects layer by layer in a manner similar to a 2D printer with the "printed" layers stacked on top of each other. The layer-wise manufacturing nature of AM enables fabrication of freeform geometries which cannot be fabricated using conventional manufacturing methods as a one part. Depending on how each layer is created and bonded to the adjacent layers, different AM methods have been developed. In this chapter, the basic terms, common materials, and different methods of AM are described, and their potential applications are discussed.}, language = {en} } @inproceedings{ChavezBermudezWollert2019, author = {Chavez Bermudez, Victor Francisco and Wollert, J{\"o}rg}, title = {Gateway for Automation Controllers and Cloud based Voice Recognition Services}, series = {KommA, 10. Jahreskolloquium Kommunikation in der Automation}, booktitle = {KommA, 10. Jahreskolloquium Kommunikation in der Automation}, publisher = {Institut f{\"u}r Automation und Kommunikation}, address = {Magdeburg}, organization = {KommA, 2019, Jahreskolloquium Kommunikation in der Automation, 10., Lemgo, DE, 2019-11-20 - 2019-11-21}, isbn = {978-3-944722-85-6}, pages = {1 -- 8}, year = {2019}, language = {en} } @incollection{GebhardtHoetter2019, author = {Gebhardt, Andreas and Hoetter, Jan-Steffen}, title = {Rapid Tooling}, series = {CIRP Encyclopedia of Production Engineering}, booktitle = {CIRP Encyclopedia of Production Engineering}, publisher = {Springer}, address = {Berlin, Heidelberg}, isbn = {978-3-662-53120-4}, doi = {10.1007/978-3-662-53120-4}, pages = {39 -- 52}, year = {2019}, language = {en} } @inproceedings{ChavezBermudezWollert2020, author = {Chavez Bermudez, Victor Francisco and Wollert, J{\"o}rg}, title = {Arduino based Framework for Rapid Application Development of a Generic IO-Link interface}, series = {Kommunikation und Bildverarbeitung in der Automation}, booktitle = {Kommunikation und Bildverarbeitung in der Automation}, publisher = {Springer Vieweg}, address = {Berlin}, isbn = {978-3-662-59895-5}, doi = {10.1007/978-3-662-59895-5_2}, pages = {21 -- 33}, year = {2020}, abstract = {The implementation of IO-Link in the automation industry has increased over the years. Its main advantage is it offers a digital point-to-point plugand-play interface for any type of device or application. This simplifies the communication between devices and increases productivity with its different features like self-parametrization and maintenance. However, its complete potential is not always used. The aim of this paper is to create an Arduino based framework for the development of generic IO-Link devices and increase its implementation for rapid prototyping. By generating the IO device description file (IODD) from a graphical user interface, and further customizable options for the device application, the end-user can intuitively develop generic IO-Link devices. The peculiarity of this framework relies on its simplicity and abstraction which allows to implement any sensor functionality and virtually connect any type of device to an IO-Link master. This work consists of the general overview of the framework, the technical background of its development and a proof of concept which demonstrates the workflow for its implementation.}, language = {en} } @inproceedings{KaschSchmidtEichleretal.2020, author = {Kasch, Susanne and Schmidt, Thomas and Eichler, Fabian and Thurn, Laura and Jahn, Simon and Bremen, Sebastian}, title = {Solution approaches and process concepts for powder bed-based melting of glass}, series = {Industrializing Additive Manufacturing. Proceedings of AMPA2020}, booktitle = {Industrializing Additive Manufacturing. Proceedings of AMPA2020}, publisher = {Springer}, address = {Cham}, isbn = {978-3-030-54333-4 (Print)}, doi = {10.1007/978-3-030-54334-1_7}, pages = {82 -- 95}, year = {2020}, abstract = {In the study, the process chain of additive manufacturing by means of powder bed fusion will be presented based on the material glass. In order to reliably process components additively, new concepts with different solutions were developed and investigated. Compared to established metallic materials, the properties of glass materials differ significantly. Therefore, the process control was adapted to the material glass in the investigations. With extensive parameter studies based on various glass powders such as borosilicate glass and quartz glass, scientifically proven results on powder bed fusion of glass are presented. Based on the determination of the particle properties with different methods, extensive investigations are made regarding the melting behavior of glass by means of laser beams. Furthermore, the experimental setup was steadily expanded. In addition to the integration of coaxial temperature measurement and regulation, preheating of the building platform is of major importance. This offers the possibility to perform 3D printing at the transformation temperatures of the glass materials. To improve the component's properties, the influence of a subsequent heat treatment was also investigated. The experience gained was incorporated into a new experimental system, which allows a much better exploration of the 3D printing of glass. Currently, studies are being conducted to improve surface texture, building accuracy, and geometrical capabilities using three-dimensional specimen. The contribution shows the development of research in the field of 3D printing of glass, gives an insight into the machine and process engineering as well as an outlook on the possibilities and applications.}, 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{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} } @article{SchwarzGebhardtSchleseretal.2019, author = {Schwarz, Alexander and Gebhardt, Andreas and Schleser, Markus and Popoola, Patricia}, title = {New Welding Joint Geometries Manufactured by Powder Bed Fusion from 316L}, series = {Materials Performance and Characterization 8}, journal = {Materials Performance and Characterization 8}, number = {in press}, issn = {2379-1365}, doi = {10.1520/MPC20180096}, year = {2019}, language = {en} } @article{CosmaKesslerGebhardtetal.2020, author = {Cosma, Cosmin and Kessler, Julia and Gebhardt, Andreas and Campbell, Ian and Balc, Nicolae}, title = {Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed}, series = {Materials}, volume = {13}, journal = {Materials}, number = {4}, publisher = {MDPI}, address = {Basel}, issn = {1996-1944}, doi = {10.3390/ma13040905}, pages = {1 -- 18}, year = {2020}, abstract = {To manufacture custom medical parts or scaffolds with reduced defects and high mechanical characteristics, new research on optimizing the selective laser melting (SLM) parameters are needed. In this work, a biocompatible powder, 316L stainless steel, is characterized to understand the particle size, distribution, shape and flowability. Examination revealed that the 316L particles are smooth, nearly spherical, their mean diameter is 39.09 μm and just 10\% of them hold a diameter less than 21.18 μm. SLM parameters under consideration include laser power up to 200 W, 250-1500 mm/s scanning speed, 80 μm hatch spacing, 35 μm layer thickness and a preheated platform. The effect of these on processability is evaluated. More than 100 samples are SLM-manufactured with different process parameters. The tensile results show that is possible to raise the ultimate tensile strength up to 840 MPa, adapting the SLM parameters for a stable processability, avoiding the technological defects caused by residual stress. Correlating with other recent studies on SLM technology, the tensile strength is 20\% improved. To validate the SLM parameters and conditions established, complex bioengineering applications such as dental bridges and macro-porous grafts are SLM-processed, demonstrating the potential to manufacture medical products with increased mechanical resistance made of 316L.}, language = {en} } @inproceedings{UlmerBraunLaietal.2019, author = {Ulmer, Jessica and Braun, Sebastian and Lai, Chow Yin and Cheng, Chi-Tsun and Wollert, J{\"o}rg}, title = {Generic integration of VR and AR in product lifecycles based on CAD models}, series = {Proceedings of The 23rd World Multi-Conference on Systemics, Cybernetics and Informatics: WMSCI 2019}, booktitle = {Proceedings of The 23rd World Multi-Conference on Systemics, Cybernetics and Informatics: WMSCI 2019}, year = {2019}, language = {en} } @inproceedings{GerhardsSchleserOttenetal.2019, author = {Gerhards, Benjamin and Schleser, Markus and Otten,, Christian and Schwarz, Alexander and Gebhardt, Andreas}, title = {Innovative Laser Beam Joining Technology for Additive Manufactured Parts}, series = {Conference Proceedings 72nd IIW Annual Assembly and International Conference, 7-12 July 2019, Bratislava}, booktitle = {Conference Proceedings 72nd IIW Annual Assembly and International Conference, 7-12 July 2019, Bratislava}, pages = {1 -- 8}, year = {2019}, language = {en} } @inproceedings{GerhardsSchleserOtten2019, author = {Gerhards, Benjamin and Schleser, Markus and Otten, Christian}, title = {Advancements of mobile vacuum laser welding for industrial thick sheet applications}, series = {Conference Proceedings 72nd IIW Annual Assembly and International Conference, 7-12 July 2019, Bratislava}, booktitle = {Conference Proceedings 72nd IIW Annual Assembly and International Conference, 7-12 July 2019, Bratislava}, pages = {1 -- 8}, year = {2019}, language = {en} } @inproceedings{BraunChengLaietal.2019, author = {Braun, Sebastian and Cheng, Chi-Tsun and Lai, Chow Yin and Wollert, J{\"o}rg}, title = {Microservice Architecture for Automation - Realization by the example of a model-factory's manufacturing execution system}, series = {Proceedings of the 23rd World Multi-Conference on Systemics, Cybernetics and Informatics: WMSCI 2019}, booktitle = {Proceedings of the 23rd World Multi-Conference on Systemics, Cybernetics and Informatics: WMSCI 2019}, pages = {33 -- 37}, year = {2019}, language = {en} } @incollection{EngemannDuKallweitetal.2020, author = {Engemann, Heiko and Du, Shengzhi and Kallweit, Stephan and Ning, Chuanfang and Anwar, Saqib}, title = {AutoSynPose: Automatic Generation of Synthetic Datasets for 6D Object Pose Estimation}, series = {Machine Learning and Artificial Intelligence. Proceedings of MLIS 2020}, booktitle = {Machine Learning and Artificial Intelligence. Proceedings of MLIS 2020}, publisher = {IOS Press}, address = {Amsterdam}, isbn = {978-1-64368-137-5}, doi = {10.3233/FAIA200770}, pages = {89 -- 97}, year = {2020}, abstract = {We present an automated pipeline for the generation of synthetic datasets for six-dimension (6D) object pose estimation. Therefore, a completely automated generation process based on predefined settings is developed, which enables the user to create large datasets with a minimum of interaction and which is feasible for applications with a high object variance. The pipeline is based on the Unreal 4 (UE4) game engine and provides a high variation for domain randomization, such as object appearance, ambient lighting, camera-object transformation and distractor density. In addition to the object pose and bounding box, the metadata includes all randomization parameters, which enables further studies on randomization parameter tuning. The developed workflow is adaptable to other 3D objects and UE4 environments. An exemplary dataset is provided including five objects of the Yale-CMU-Berkeley (YCB) object set. The datasets consist of 6 million subsegments using 97 rendering locations in 12 different UE4 environments. Each dataset subsegment includes one RGB image, one depth image and one class segmentation image at pixel-level.}, language = {en} }