TY - CHAP A1 - Bagheri, Mohsen A1 - Schleupen, Josef A1 - Dahmann, Peter A1 - Kallweit, Stephan T1 - Kletternde Wartungsplattform für die wetterunabhängige Instandhaltung von Rotorblättern an Windenergieanlagen - SMART T2 - AKIDA 2016 Aachener Kolloquium für Instandhaltung, Diagnose und Anlagenüberwachung (AKIDA) am 15. und 16.11.2016, Technologiezentrum Aachen N2 - In Deutschland liegt der Anteil der Windkraft an der Gesamtstromerzeugung bei 13,3% mit mehr als 25.000 installierten Windenergieanlagen (WEA). Weltweit erfährt die Windbranche ein rasantes Wachstum. Indien und China berichten eine jährliche Wachstumsrate an Neuinstallationen von 45%. Die Technologie zur Erzeugung elektrischer Energie aus Windkraft ist noch vergleichsweise jung. Durch die weltweit steigende Anzahl an Windenergieanlagen wächst zunehmend der Bedarf an innovativen Wartungslösungen. Komponenten wie Generator oder Getriebe sind inzwischen weitestgehend ausgereift. Der Fokus richtet sich zunehmend auf die wesentliche Kernkomponente - die Rotorblätter. Industriekletterer inspizieren die Rotorblätter oder Türme i.d.R. in einem zwei Jahres Rhythmus. Sie werden zunehmend durch Seilarbeitsbühnen unterstützt. Für größere Reparaturen kommen Kräne zum Einsatz, mit denen das Rotorblatt für die Instandhaltung demontiert wird. Die Standardinspektion besteht aus Sicht- und Klopfprüfung der Rotorblattoberfläche und ist nur bei sehr ruhiger Wetterlage durchführbar. Seit September 2014 wird das Forschungsprojekt SMART (Scanning, Monitoring, Analysis, Repair and Transportation), Entwicklung einer Wartungsplattform für WEA, vom BMWi gefördert. Das Konsortium besteht aus zwei Firmen und der Fachhochschule Aachen. Die SMART-Anlage klettert reibschlüssig am Turm der WEA mittels speziellen Kettenfahrwerken (Abbildung) auf- und abwärts. Ein ringförmiges Spannsystems, basierend auf dem Konzept der „Nürnberger“-Schere, erzeugt die erforderliche Anpresskraft für den Kletterprozess. Wettergeschützte Arbeitskabinen ermöglichen die ganzjährige Instandhaltung von Rotorblättern und ebenso Türmen. Dadurch können 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 Qualität der Instandhaltungsarbeiten erheblich verbessern. Langfristiges Ziel von SMART ist ein Condition Monitoring für Rotorblätter und Türme auf Basis digitalisierter dreidimensionaler Volumenscans. Der kooperative Einsatz mit UAVs erweitert die Instandhaltungsstrategie. UAVs ermöglichen die schnelle, kostengünstige globale optische Inspektion von Rotorblattoberflächen zur Detektion potentieller Fehlstellen. Der „Proof-of-Concept“ Meilenstein wurde mit der Demonstration eines funktionsfähigen Modells im Dezember 2015 erfolgreich abgeschlossen. Y1 - 2016 ER - TY - JOUR A1 - Michaux, F. A1 - Mattern, P. A1 - Kallweit, Stephan T1 - RoboPIV: how robotics enable PIV on a large industrial scale JF - Measurement Science and Technology N2 - 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. Y1 - 2018 U6 - https://doi.org/10.1088/1361-6501/aab5c1 SN - 1361-6501 N1 - Special Section on the 12th International Symposium on Particle Image Velocimetry (PIV 2017) VL - 29 IS - 7 SP - 074009 PB - IOP CY - Bristol ER - TY - JOUR A1 - Kunkel, Maximilian Hugo A1 - Gebhardt, Andreas A1 - Mpofu, Khumbaulani A1 - Kallweit, Stephan T1 - Statistical assessment of mechanical properties of selective laser melted specimens of stainless steel JF - The International Journal of Advanced Manufacturing Technology N2 - 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. Y1 - 2018 U6 - https://doi.org/10.1007/s00170-018-2040-8 SN - 0268-3768 VL - 98 IS - 5-8 SP - 1409 EP - 1431 PB - Springer CY - London ER - TY - JOUR A1 - Limpert, Nicolas A1 - Wiesen, Patrick A1 - Ferrein, Alexander A1 - Kallweit, Stephan A1 - Schiffer, Stefan T1 - The ROSIN Project and its Outreach to South Africa JF - R&D Journal Y1 - 2019 VL - 35 SP - 1 EP - 6 ER - TY - CHAP A1 - Kleine, Harald A1 - Kallweit, Stephan A1 - Michaux, Frank A1 - Havermann, Marc A1 - Olivier, Herbert T1 - PIV Measurement of Shock Wave Diffraction T2 - 18th International Symposium on Applications of Laser Techniques to Fluid Mechanics, 2016, Lissabon Y1 - 2016 SP - 1 EP - 14 ER - TY - CHAP A1 - Schleupen, Josef A1 - Engemann, Heiko A1 - Bagheri, Mohsen A1 - Kallweit, Stephan T1 - The potential of SMART climbing robot combined with a weatherproof cabin for rotor blade maintenance T2 - 17th European Conference on Composite Materials – ECCM, Munich, Germany Y1 - 2016 N1 - ECCM 17 SP - 1 EP - 8 ER - TY - CHAP A1 - Wiesen, Patrick A1 - Engemann, Heiko A1 - Limpert, Nicolas A1 - Kallweit, Stephan T1 - Learning by Doing - Mobile Robotics in the FH Aachen ROS Summer School T2 - European Robotics Forum 2018, TRROS18 Workshop Y1 - 2018 SP - 47 EP - 58 ER - TY - JOUR A1 - Engemann, Heiko A1 - Cönen, Patrick A1 - Dawar, Harshal A1 - Du, Shengzhi A1 - Kallweit, Stephan T1 - A robot-assisted large-scale inspection of wind turbine blades in manufacturing using an autonomous mobile manipulator JF - Applied Sciences N2 - 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. KW - mobile manipulation KW - large-scale inspection KW - wind turbine production KW - autonomous navigation KW - surface-orthogonal path planning Y1 - 2021 U6 - https://doi.org/10.3390/app11199271 SN - 2076-3417 N1 - Belongs to the Special Issue "Advances in Industrial Robotics and Intelligent Systems" VL - 11 IS - 19 SP - 1 EP - 22 PB - MDPI CY - Basel ER - TY - CHAP A1 - Engemann, Heiko A1 - Wiesen, Patrick A1 - Kallweit, Stephan A1 - Deshpande, Harshavardhan A1 - Schleupen, Josef T1 - Autonomous mobile manipulation using ROS T2 - Advances in Service and Industrial Robotics Y1 - 2018 SN - 978-3-319-61276-8 U6 - https://doi.org/10.1007/978-3-319-61276-8_43 N1 - International Conference on Robotics in Alpe-Adria Danube Region RAAD 2017; Mechanisms and Machince Science book series, Vol 49. SP - 389 EP - 401 PB - Springer CY - Cham ER - TY - CHAP A1 - Engemann, Heiko A1 - Badri, Sriram A1 - Wenning, Marius A1 - Kallweit, Stephan T1 - Implementation of an Autonomous Tool Trolley in a Production Line T2 - Advances in Service and Industrial Robotics. RAAD 2019. Advances in Intelligent Systems and Computing, vol 980 Y1 - 2019 SN - 978-3-030-19648-6 U6 - https://doi.org/10.1007/978-3-030-19648-6_14 SP - 117 EP - 125 PB - Springer CY - Cham ER -