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Digital twins are seen as one of the key technologies of Industry 4.0. Although many research groups focus on digital twins and create meaningful outputs, the technology has not yet reached a broad application in the industry. The main reasons for this imbalance are the complexity of the topic, the lack of specialists, and the unawareness of the twin opportunities. The project "Digital Twin Academy" aims to overcome these barriers by focusing on three actions: Building a digital twin community for discussion and exchange, offering multi-stage training for various knowledge levels, and implementing realworld use cases for deeper insights and guidance. In this work, we focus on creating a flexible learning platform that allows the user to select a training path adjusted to personal knowledge and needs. Therefore, a mix of basic and advanced modules is created and expanded by individual feedback options. The usage of personas supports the selection of the appropriate modules.
Adapting augmented reality systems to the users’ needs using gamification and error solving methods
(2021)
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.
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.
Virtual Reality (VR) offers novel possibilities for remote training regardless of the availability of the actual equipment, the presence of specialists, and the training locations. Research shows that training environments that adapt to users' preferences and performance can promote more effective learning. However, the observed results can hardly be traced back to specific adaptive measures but the whole new training approach. This study analyzes the effects of a combined point and leveling VR-based gamification system on assembly training targeting specific training outcomes and users' motivations. The Gamified-VR-Group with 26 subjects received the gamified training, and the Non-Gamified-VR-Group with 27 subjects received the alternative without gamified elements. Both groups conducted their VR training at least three times before assembling the actual structure. The study found that a level system that gradually increases the difficulty and error probability in VR can significantly lower real-world error rates, self-corrections, and support usages. According to our study, a high error occurrence at the highest training level reduced the Gamified-VR-Group's feeling of competence compared to the Non-Gamified-VR-Group, but at the same time also led to lower error probabilities in real-life. It is concluded that a level system with a variable task difficulty should be combined with carefully balanced positive and negative feedback messages. This way, better learning results, and an improved self-evaluation can be achieved while not causing significant impacts on the participants' feeling of competence.
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.
Assistance systems have been widely adopted in the manufacturing sector to facilitate various processes and tasks in production environments. However, existing systems are mostly equipped with rigid functional logic and do not provide individual user experiences or adapt to their capabilities. This work integrates human factors in assistance systems by adjusting the hardware and instruction presented to the workers’ cognitive and physical demands. A modular system architecture is designed accordingly, which allows a flexible component exchange according to the user and the work task. Gamification, the use of game elements in non-gaming contexts, has been further adopted in this work to provide level-based instructions and personalised feedback. The developed framework is validated by applying it to a manual workstation for industrial assembly routines.
This paper presents the laser-based powder bed fusion (L-PBF) using various glass powders (borosilicate and quartz glass). Compared to metals, these require adapted process strategies. First, the glass powders were characterized with regard to their material properties and their processability in the powder bed. This was followed by investigations of the melting behavior of the glass powders with different laser wavelengths (10.6 µm, 1070 nm). In particular, the experimental setup of a CO2 laser was adapted for the processing of glass powder. An experimental setup with integrated coaxial temperature measurement/control and an inductively heatable build platform was created. This allowed the L-PBF process to be carried out at the transformation temperature of the glasses. Furthermore, the component’s material quality was analyzed on three-dimensional test specimen with regard to porosity, roughness, density and geometrical accuracy in order to evaluate the developed L-PBF parameters and to open up possible applications.
The potential of SMART climbing robot combined with a weatherproof cabin for rotor blade maintenance
(2016)
We present a new Min-Max theorem for an optimization problem closely connected to matchings and vertex covers in balanced hypergraphs. The result generalizes Kőnig’s Theorem (Berge and Las Vergnas in Ann N Y Acad Sci 175:32–40, 1970; Fulkerson et al. in Math Progr Study 1:120–132, 1974) and Hall’s Theorem (Conforti et al. in Combinatorica 16:325–329, 1996) for balanced hypergraphs.
The aim of this work was to perform a detailed investigation of the use of Selective Laser Melting (SLM) technology to process eutectic silver-copper alloy Ag 28 wt. % Cu (also called AgCu28). The processing occurred with a Realizer SLM 50 desktop machine. The powder analysis (SEM-topography, EDX, particle distribution) was reported as well as the absorption rates for the near-infrared (NIR) spectrum. Microscope imaging showed the surface topography of the manufactured parts. Furthermore, microsections were conducted for the analysis of porosity. The Design of Experiments approach used the response surface method in order to model the statistical relationship between laser power, spot distance and pulse time.
Bead-on-plate butt joints of 2.5 mm hot rolled DP600/DP600 and 1.2 mm cold rolled TRIP700/TRIP700 steel sheets were performed using 6 kW CO2 laser beam welding. The welding speed ranged from 1.5 to 3.0 and from 2.1 to 3.9 m/min in DP/DP and TRIP/TRIP steel weldments respectively. A top surface helium gas was used as a shielding gas at a flow rate of 20 l/min. Metallographic examinations and transverse tensile testing (DIN EN 895: 1995) were carried out to characterize the weldments. The formability of base metals and weldments were investigated by standard Erichsen test (DIN EN ISO 20482). It was found that the uniaxial plastic behavior of both DP600 and TRIP700 base metals was in agreement with Swift and modified Mecking–Kocks models respectively. In a perpendicular tensile test to the weld line, all specimens were fractured at the base metal however the strengths were somewhat higher than those of base metal. There was a significant reduction in formability caused by welding of both DP/DP and TRIP/TRIP steel weldments and the formability has been improved with the increase of the welding speed.
Shielding gas influences on laser weldability of tailored blanks of advanced automotive steels
(2010)
The effects of shielding gas types and flow rates on CO2 laser weldability of DP600/TRIP700 steel sheets were studied in this work. The evaluated shielding gases were helium (He), argon (Ar) and different mixtures of He and Ar. Weld penetration, tensile strength and formability (Erichsen test) of laser welds were found to be strongly dependent upon the shielding gas types. The ability of shielding gas in removing plasma plume and thus increasing weld penetration is believed to be closely related to ionization potential and atomic weight which determine the period of plasma formation and disappearance. It was found that the higher helium shielding gas flow rate, the deeper weld penetration and the lower weld width.