Fachbereich Maschinenbau und Mechatronik
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Die fortschreitende Digitalisierung und Globalisierung fordert von den Unternehmen eine erhöhte Flexibilität und Anpassungsfähigkeit. Um dies zu erreichen, sind qualifizierte und engagierte Mitarbeiter/-innen unabdingbar. Gamification bietet die Möglichkeit, Beschäftigte individuell in ihren Tätigkeiten zu unterstützen und mittels Feedbackmechanismen zu motivieren. In dieser Arbeit wird ein Gamification Konzept bestehend aus einem intelligenten Arbeitsplatz, einer Wissensdatenbank und einer Gamification Plattform vorgestellt, welches an bestehende Produktionsumgebungen adaptiert werden kann. Das Konzept wird am Beispiel der Longboardproduktion in der Industrie 4.0 Modellfabrik der FH Aachen implementiert und evaluiert.
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.
Berücksichtigung von No Fault Found im Diagnose- und Instandhaltungssystem von Schienenfahrzeugen
(2020)
Intermittierende und nicht reproduzierbare Fehler, auch als No Fault Found bezeichnet, treten in praktisch allen Bereichen auf und sorgen für hohe Kosten. Diese sind häufig auf unpräzise Fehlerbeschreibungen zurückzuführen. Im vorliegenden Beitrag werden Anpassungen der Vorgehensweise bei der Entwicklung und Anpassungen des Diagnosesystems vorgeschlagen.
Neue Perspektiven für die Bahn in der Produktions- und Distributionslogistik durch Prozessautomation
(2020)
Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed
(2020)
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.
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.
Entwicklung einer Qualitätssicherung für das Laserstrahlschweißen im Vakuum mittels Bildverarbeitung
(2019)
Tribological performance of biodegradable lubricants under different surface roughness of tools
(2019)
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.
Wenn durch innovative, automatisierte Güterwagen betriebswirtschaftliche Vorteile nutzbar gemacht werden sollen, muss die Migration auf das neue System in sinnvollen Teilschritten unter Berücksichtigung der organisationellen und betrieblichen Vereinbarkeit vorgenommen werden. Eine stufenweise Migration mit Nachrüstbarkeit und Kompatibilität kann die optimale Ausstattungsvariante für die unterschiedlichen Betriebsszenarien sowie eine Steigerung der Wirtschaftlichkeit des Gesamtsystems bieten.
Rare event simulation to optimise maintenance intervals of safety critical redundant subsystems
(2018)
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.
Sensor positioning and thermal model for condition monitoring of pressure gas reservoirs in vehicles
(2018)
Bereits 2015 wurde in der Zeitschrift „Qualität in der Wissenschaft“ (QiW) über das Kooperationsprojekt „Guter Studienstart im Ingenieurbereich“, das Orientierungssemester von RWTH und FH Aachen, berichtet. In diesem Artikel legen wir den Schwerpunkt auf die Entwicklung des Projekts in den Jahren 2015 bis 2018 und geben eine Rückschau sowie einen Ausblick auf die Entwicklungsperspektiven nach dem offiziellen Projektende.
Das Forschungsprojekt Produktionseffizienz in der Kleinserie (ProeK) erarbeitet kostengünstige und effiziente Lösungsansätze für Prozessketten im Zukunftsfeld der Elektromobilität. Das Teilprojekt Karosserie setzt diese Zielsetzung durch innovative und praxisorientierte Produkt- und Prozesskonzepte mit neuartigen bauteilintegrierten Vorrichtungsfunktionen (BiV) um. Im Teilprojekt Außenhaut sollen Toleranzen adaptiv durch Anpassungen der Prozessparameter sowie Bauteilmanipulation kompensiert werden.
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.
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.