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A research framework for human aspects in the internet of production: an intra-company perspective
(2020)
Digitalization in the production sector aims at transferring concepts and methods from the Internet of Things (IoT) to the industry and is, as a result, currently reshaping the production area. Besides technological progress, changes in work processes and organization are relevant for a successful implementation of the “Internet of Production” (IoP). Focusing on the labor organization and organizational procedures emphasizes to consider intra-company factors such as (user) acceptance, ethical issues, and ergonomics in the context of IoP approaches. In the scope of this paper, a research approach is presented that considers these aspects from an intra-company perspective by conducting studies on the shop floor, control level and management level of companies in the production area. Focused on four central dimensions—governance, organization, capabilities, and interfaces—this contribution presents a research framework that is focused on a systematic integration and consideration of human aspects in the realization of the IoP.
The recovery of waste heat requires heat exchangers to extract it from a liquid or gaseous medium into another working medium, a refrigerant. In Organic Rankine Cycles (ORC) on Combustion Engines there are two major heat sources, the exhaust gas and the water/glycol fluid from the engine’s cooling circuit. A heat exchanger design must be adapted to the different requirements and conditions resulting from the heat sources, fluids, system configurations, geometric restrictions, and etcetera. The Stacked Shell Cooler (SSC) is a new and very specific design of a plate heat exchanger, created by AKG, which allows with a maximum degree of freedom the optimization of heat exchange rate and the reduction of the related pressure drop. This optimization in heat exchanger design for ORC systems is even more important, because it reduces the energy consumption of the system and therefore maximizes the increase in overall efficiency of the engine.
Water suppliers are faced with the great challenge of achieving high-quality and, at the same time, low-cost water supply. Since climatic and demographic influences will pose further challenges in the future, the resilience enhancement of water distribution systems (WDS), i.e. the enhancement of their capability to withstand and recover from disturbances, has been in particular focus recently. To assess the resilience of WDS, graph-theoretical metrics have been proposed. In this study, a promising approach is first physically derived analytically and then applied to assess the resilience of the WDS for a district in a major German City. The topology based resilience index computed for every consumer node takes into consideration the resistance of the best supply path as well as alternative supply paths. This resistance of a supply path is derived to be the dimensionless pressure loss in the pipes making up the path. The conducted analysis of a present WDS provides insight into the process of actively influencing the resilience of WDS locally and globally by adding pipes. The study shows that especially pipes added close to the reservoirs and main branching points in the WDS result in a high resilience enhancement of the overall WDS.
The development of resilient technical systems is a challenging task, as the system should adapt automatically to unknown disturbances and component failures. To evaluate different approaches for deriving resilient technical system designs, we developed a modular test rig that is based on a pumping system. On the basis of this example
system, we present metrics to quantify resilience and an algorithmic approach to improve resilience. This approach enables the pumping system to automatically react on unknown disturbances and to reduce the impact of component failures. In this case, the system is able to automatically adapt its topology by activating additional valves. This enables the system to still reach a minimum performance, even in case of failures. Furthermore, timedependent disturbances are evaluated continuously, deviations from the original state are automatically detected and anticipated in the future. This allows to reduce the impact of future disturbances and leads to a more resilient
system behaviour.
The chemical industry is one of the most important industrial sectors in Germany in terms of manufacturing revenue. While thermodynamic boundary conditions often restrict the scope for reducing the energy consumption of core processes, secondary processes such as cooling offer scope for energy optimisation. In this contribution, we therefore model and optimise an existing cooling system. The technical boundary conditions of the model are provided by the operators, the German chemical company BASF SE. In order to systematically evaluate different degrees of freedom in topology and operation, we formulate and solve a Mixed-Integer Nonlinear Program (MINLP), and compare our optimisation results with the existing system.
Successful optimization requires an appropriate model of the system under consideration. When selecting a suitable level of detail, one has to consider solution quality as well as the computational and implementation effort. In this paper, we present a MINLP for a pumping system for the drinking water supply of high-rise buildings. We investigate the influence of the granularity of the underlying physical models on the solution quality. Therefore, we model the system with a varying level of detail regarding the friction losses, and conduct an experimental validation of our model on a modular test rig. Furthermore, we investigate the computational effort and show that it can be reduced by the integration of domain-specific knowledge.
Water distribution systems are an essential supply infrastructure for cities. Given that climatic and demographic influences will pose further challenges for these infrastructures in the future, the resilience of water supply systems, i.e. their ability to withstand and recover from disruptions, has recently become a subject of research. To assess the resilience of a WDS, different graph-theoretical approaches exist. Next to general metrics characterizing the network topology, also hydraulic and technical restrictions have to be taken into account. In this work, the resilience of an exemplary water distribution network of a major German city is assessed, and a Mixed-Integer Program is presented which allows to assess the impact of capacity adaptations on its resilience.
To maximize the travel distances of battery electric vehicles such as cars or buses for a given amount of stored energy, their powertrains are optimized energetically. One key part within optimization models for electric powertrains is the efficiency map of the electric motor. The underlying function is usually highly nonlinear and nonconvex and leads to major challenges within a global optimization process. To enable faster solution times, one possibility is the usage of piecewise linearization techniques to approximate the nonlinear efficiency map with linear constraints. Therefore, we evaluate the influence of different piecewise linearization modeling techniques on the overall solution process and compare the solution time and accuracy for methods with and without explicitly used binary variables.
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.
Thematisch widmet sich das Projekt Coolplan- AIR der Fortentwicklung und Feldvalidierung eines Berechnungs- und Auslegungstools zur energieeffizienten Kühlung von Gebäuden mit luftgestützten Systemen. Neben dem Aufbau und der Weiterentwicklung von Simulationsmodellen erfolgen Vermessungen der Gesamtsysteme anhand von Praxisanlagen im Feld. Der Schwerpunkt des Projekts liegt auf der Vermessung, Simulation und Integration rein luftgestützter Kühltechnologien. Im Bereich der Kälteerzeugung wurden Luft‐ Luft‐ Wärmepumpen, Anlagen zur adiabaten Kühlung bzw. offene Kühltürme und VRF‐ Multisplit‐ Systeme (Variable Refrigerant Flow) im Feld bzw. auf dem Teststand der HSD vermessen. Die Komponentenmodelle werden in die Matlab/Simulink‐ Toolbox CARNOT integriert und anschließend auf Basis der zuvor erhaltenen Messdaten validiert.
Einerseits erlauben die Messungen das Betriebsverhalten von Anlagenkomponenten zu analysieren. Andererseits soll mit der Vermessung im Feld geprüft werden, inwieweit die Simulationsmodelle, welche im Vorgängerprojekt aus Prüfstandmessungen entwickelt wurden, auch für größere Geräteleistungen Gültigkeit besitzen. Die entwickelten und implementierten Systeme, bestehend aus verschiedensten Anlagenmodellen und Regelungskomponenten, werden geprüft und dahingehend qualifiziert, dass sie in Standard- Auslegungstools zuverlässig verwendet werden können.
Zusätzlich wird ein energetisches Monitoring eines Hörsaalgebäudes am Campus Jülich durchgeführt, das u. a. zur Validierung der Kühllastberechnungen in gängigen Simulationsmodelle genutzt werden kann.
Im Projekt Coolplan‐ AIR geht es um die Fortentwicklung und Feld‐ Validierung eines Berechnungs‐ und Auslegungstools zur energieeffizienten Kühlung von Gebäuden mit luftgestützten Systemen. Neben dem Aufbau und der Weiterentwicklung von Simulationsmodellen erfolgen Vermessungen der Gesamtsysteme anhand von Praxisanlagen im Feld. Eine der betrachteten Anlagen arbeitet mit indirekter Verdunstung. Diese Veröffentlichung zeigt den Entwicklungsprozess und den Aufbau des Simulationsmodells zur Verdunstungskühlung in der Simulationsumgebung Matlab‐ Simulink mit der CARNOT‐ Toolbox. Das besondere Augenmerk liegt dabei auf dem physikalischen Modell des Wärmeübertragers, in dem die Verdunstung implementiert ist. Dem neuen Modellansatz liegt die Annahme einer aus der Enthalpie‐ Betrachtung hergeleiteten effektiven Wärmekapazität zugrunde. Des Weiteren wird der Befeuchtungsgrad als konstant angesehen und eine standardisierte Zunahme der Wärmeübertragung des feuchten gegenüber dem trockenen Wärmeübertrager angenommen. Die Validierung des Modells erfolgte anhand von Literaturdaten. Für den trockenen Wärmetauscher ist der maximale absolute Fehler der berechneten Austrittstemperatur (Zuluft) kleiner als ±0.1 K und für den nassen Wärmetauscher (Kühlfall) unter der Annahme eines konstanten Verdunstungsgrades kleiner als ±0.4 K.
Modeling and upscaling of a pilot bayonettube reactor for indirect solar mixed methane reforming
(2020)
A 16.77 kW thermal power bayonet-tube reactor for the mixed reforming of methane using solar energy has been designed and modeled. A test bench for the experimental tests has been installed at the Synlight facility in Juelich, Germany and has just been commissioned. This paper presents the solar-heated reactor design for a combined steam and dry reforming as well as a scaled-up process simulation of a solar reforming plant for methanol production. Solar power towers are capable of providing large amounts of heat to drive high-endothermic reactions, and their integration with thermochemical processes shows a promising future. In the designed bayonet-tube reactor, the conventional burner arrangement for the combustion of natural gas has been substituted by a continuous 930 °C hot air stream, provided by means of a solar heated air receiver, a ceramic thermal storage and an auxiliary firing system. Inside the solar-heated reactor, the heat is transferred by means of convective mechanism mainly; instead of radiation mechanism as typically prevailing in fossil-based industrial reforming processes. A scaled-up solar reforming plant of 50.5 MWth was designed and simulated in Dymola® and AspenPlus®. In comparison to a fossil-based industrial reforming process of the same thermal capacity, a solar reforming plant with thermal storage promises a reduction up to 57 % of annual natural gas consumption in regions with annual DNI-value of 2349 kWh/m2. The benchmark solar reforming plant contributes to a CO2 avoidance of approx. 79 kilotons per year. This facility can produce a nominal output of 734.4 t of synthesis gas and out of this 530 t of methanol a day.
As part of the transnational research project EDITOR, a parabolic trough collector system (PTC) with concrete thermal energy storage (C-TES) was installed and commissioned in Limassol, Cyprus. The system is located on the premises of the beverage manufacturer KEAN Soft Drinks Ltd. and its function is to supply process steam for the factory's pasteurisation process [1]. Depending on the factory's seasonally varying capacity for beverage production, the solar system delivers between 5 and 25 % of the total steam demand. In combination with the C-TES, the solar plant can supply process steam on demand before sunrise or after sunset. Furthermore, the C-TES compensates the PTC during the day in fluctuating weather conditions. The parabolic trough collector as well as the control and oil handling unit is designed and manufactured by Protarget AG, Germany. The C-TES is designed and produced by CADE Soluciones de Ingeniería, S.L., Spain. In the focus of this paper is the description of the operational experience with the PTC, C-TES and boiler during the commissioning and operation phase. Additionally, innovative optimisation measures are presented.
Industry 4.0 imposes many challenges for manufacturing companies and their employees. Innovative and effective training strategies are required to cope with fast-changing production environments and new manufacturing technologies. Virtual Reality (VR) offers new ways of on-the-job, on-demand, and off-premise training. A novel concept and evaluation system combining Gamification and VR practice for flexible assembly tasks is proposed in this paper and compared to existing works. It is based on directed acyclic graphs and a leveling system. The concept enables a learning speed which is adjustable to the users’ pace and dynamics, while the evaluation system facilitates adaptive work sequences and allows employee-specific task fulfillment. The concept was implemented and analyzed in the Industry 4.0 model factory at FH Aachen for mechanical assembly jobs.