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Gearboxes are mechanical transmission systems that provide speed and torque conversions from a rotating power source. Being a central element of the drive train, they are relevant for the efficiency and durability of motor vehicles. In this work, we present a new approach for gearbox design: Modeling the design problem as a mixed-integer nonlinear program (MINLP) allows us to create gearbox designs from scratch for arbitrary requirements and—given enough time—to compute provably globally optimal designs for a given objective. We show how different degrees of freedom influence the runtime and present an exemplary solution.
Energy-efficient components do not automatically lead to energy-efficient systems. Technical Operations Research (TOR) shifts the focus from the single component to the system as a whole and finds its optimal topology and operating strategy simultaneously. In previous works, we provided a preselected construction kit of suitable components for the algorithm. This approach may give rise to a combinatorial explosion if the preselection cannot be cut down to a reasonable number by human intuition. To reduce the number of discrete decisions, we integrate laws derived from similarity theory into the optimization model. Since the physical characteristics of a production series are similar, it can be described by affinity and scaling laws. Making use of these laws, our construction kit can be modeled more efficiently: Instead of a preselection of components, it now encompasses whole model ranges. This allows us to significantly increase the number of possible set-ups in our model. In this paper, we present how to embed this new formulation into a mixed-integer program and assess the run time via benchmarks. We present our approach on the example of a ventilation system design problem.
In the future, we expect manufacturing companies to follow a new paradigm that mandates more automation and autonomy in production processes. Such smart factories will offer a variety of production technologies as services that can be combined ad hoc to produce a large number of different product types and variants cost-effectively even in small lot sizes. This is enabled by cyber-physical systems that feature flexible automated planning methods for production scheduling, execution control, and in-factory logistics.
During development, testbeds are required to determine the applicability of integrated systems in such scenarios. Furthermore, benchmarks are needed to quantify and compare system performance in these industry-inspired scenarios at a comprehensible and manageable size which is, at the same time, complex enough to yield meaningful results.
In this chapter, based on our experience in the RoboCup Logistics League (RCLL) as a specific example, we derive a generic blueprint for how a holistic benchmark can be developed, which combines a specific scenario with a set of key performance indicators as metrics to evaluate the overall integrated system and its components.
Cyber-physical systems are ever more common in manufacturing industries. Increasing their autonomy has been declared an explicit goal, for example, as part of the Industry 4.0 vision. To achieve this system intelligence, principled and software-driven methods are required to analyze sensing data, make goal-directed decisions, and eventually execute and monitor chosen tasks. In this chapter, we present a number of knowledge-based approaches to these problems and case studies with in-depth evaluation results of several different implementations for groups of autonomous mobile robots performing in-house logistics in a smart factory. We focus on knowledge-based systems because besides providing expressive languages and capable reasoning techniques, they also allow for explaining how a particular sequence of actions came about, for example, in the case of a failure.
This paper introduces a hardware setup to measure efficiency maps of low-power electric motors and their associated inverters. Here, the power of the device under test (DUT) ranges from some Watts to a few hundred Watts. The torque and speed of the DUT are measured independent of voltage and current in multiple load points. A Matlab-based software approach in combination with an open Texas-Instruments (TI) hardware setup ensures flexibility. Exemplarily, the efficiency field of a Permanent Magnet Synchronous Machine (PMSM) is measured to proof the concept. Brushless-DC (BLDC) motors can be tested as well. The nomenclature in this paper is based on the new European standard DIN EN 50598. Special attention is paid to the calculation of the measurement error.
Die Verbindung der Welten dressierter Elektronen und grenzenloser Kreativität bietet ein großes Potential; zum Beispiel bei modernen Skulpturen, deren Form sich durch Motoren verändern kann. An der FH Aachen wurde ein solches Projekt verwirklicht: Eine Matrix aus Holzkugeln kann Piktogramme anzeigen, aber auch mathematische Funktionen visualisieren. In diesem Artikel beschreiben wir die clevere Ansteuerung der Motoren.
Control mechanisms like Industrial Controls Systems (ICS) and its subgroup SCADA (Supervisory Control and Data Acquisition) are a prerequisite to automate industrial processes. While protection of ICS on process management level is relatively straightforward – well known office IT security mechanisms can be used – protection on field bus level is harder to achieve as there are real-time and production requirements like 24x7 to consider. One option to improve security on field bus level is to introduce controls that help to detect and to react on attacks. This paper introduces an initial set of intrusion detection mechanisms for the field bus protocol EtherCAT. To this end existing Ethernet attack vectors including packet injection and man-in-the-middle attacks are tested in an EtherCAT environment, where they could interrupt the EtherCAT network and may even cause physical damage. Based on the signatures of such attacks, a preprocessor and new rule options are defined for the open source intrusion detection system Snort demonstrating the general feasibility of intrusion detection on field bus level.
ICSs (Industrial Control Systems) and its subset SCADA systems (Supervisory Control and Data Acquisition) are getting exposed to a constant stream of new threats. The increasing importance of IT security in ICS requires viable methods to assess the security of ICS, its individual components, and its protocols. This paper presents a security analysis with focus on the communication protocols of a single PLC (Programmable Logic Controller). The PLC, a Beckhoff CX2020, is examined and new vulnerabilities of the system are revealed. Based on these findings recommendations are made to improve security of the Beckhoff system and its protocols.
SAR Simulations & Safety
(2017)