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A new method for improved autoclave loading within the restrictive framework of helicopter manufacturing is proposed. It is derived from experimental and numerical studies of the curing process and aims at optimizing tooling positions in the autoclave for fast and homogeneous heat-up. The mold positioning is based on two sets of information. The thermal properties of the molds, which can be determined via semi-empirical thermal simulation. The second information is a previously determined distribution of heat transfer coefficients inside the autoclave. Finally, an experimental proof of concept is performed to show a cycle time reduction of up to 31% using the proposed methodology.
Für die Herstellung von metallischen Bauteilen wird in der heutigen Zeit eine Vielzahl von Verfahren auf dem Markt angeboten. Dabei stehen die additiven im Wettbewerb zu den konventionellen Verfahren. Die erreichbaren Oberflächenqualitäten der additiven sind nicht mit denen spanender Verfahren vergleichbar. Für diesen Beitrag wurde analysiert, ob sich ein mittels Selektivem Laserschmelzen (SLM) additiv hergestellter Edelstahl hinsichtlich seiner Oberflächenqualität nach der Zerspanung von einem umgeformten konventionell hergestellten Edelstahl gleicher Sorte unterscheidet.
For typical cases of non-isolated lightning protection systems (LPS) the impulse currents are investigated which may flow through a human body directly touching a structural part of the LPS. Based on a basic LPS model with conventional down-conductors especially the cases of external and internal steel columns and metal façades are considered and compared. Numerical simulations of the line quantities voltages and currents in the time domain are performed with an equivalent circuit of the entire LPS.
As a result it can be stated that by increasing the number of conventional down-conductors and external steel columns the threat for a human being can indeed be reduced, but not down to an acceptable limit. In case of internal steel columns used as natural down-conductors the threat can be reduced sufficiently, depending on the low-resistive connection of the steel columns to the lightning equipotential bonding or the earth termination system, resp. If a metal façade is used the threat for human beings touching is usually very low, if the façade is sufficiently interconnected and multiply connected to the lightning equipotential bonding or the earth termination system, resp.
Finding a good system topology with more than a handful of components is a
highly non-trivial task. The system needs to be able to fulfil all expected load cases, but at the
same time the components should interact in an energy-efficient way. An example for a system
design problem is the layout of the drinking water supply of a residential building. It may be
reasonable to choose a design of spatially distributed pumps which are connected by pipes in at
least two dimensions. This leads to a large variety of possible system topologies. To solve such
problems in a reasonable time frame, the nonlinear technical characteristics must be modelled
as simple as possible, while still achieving a sufficiently good representation of reality. The
aim of this paper is to compare the speed and reliability of a selection of leading mathematical
programming solvers on a set of varying model formulations. This gives us empirical evidence
on what combinations of model formulations and solver packages are the means of choice with the current state of the art.
The UN sets the goal to ensure access to water and sanitation for all people by 2030. To address this goal, we present a multidisciplinary approach for designing water supply networks for slums in large cities by applying mathematical optimization. The problem is modeled as a mixed-integer linear problem (MILP) aiming to find a network describing the optimal supply infrastructure. To illustrate the approach, we apply it on a small slum cluster in Dhaka, Bangladesh.
The overall energy efficiency of ventilation systems can be improved by considering not only single components, but by considering as well the interplay between every part of the system. With the help of the method "TOR" ("Technical Operations Research"), which was developed at the Chair of Fluid Systems at TU Darmstadt, it is possible to improve the energy efficiency of the whole system by considering all possible design choices programmatically. We show the ability of this systematic design approach with a ventilation system for buildings as a use case example.
Based on a Mixed-Integer Nonlinear Program (MINLP) we model the ventilation system. We use binary variables to model the selection of different pipe diameters. Multiple fans are model with the help of scaling laws. The whole system is represented by a graph, where the edges represent the pipes and fans and the nodes represents the source of air for cooling and the sinks, that have to be cooled. At the beginning, the human designer chooses a construction kit of different suitable fans and pipes of different diameters and different load cases. These boundary conditions define a variety of different possible system topologies. It is not possible to consider all topologies by hand. With the help of state of the art solvers, on the other side, it is possible to solve this MINLP.
Next to this, we also consider the effects of malfunctions in different components. Therefore, we show a first approach to measure the resilience of the shown example use case. Further, we compare the conventional approach with designs that are more resilient. These more resilient designs are derived by extending the before mentioned model with further constraints, that consider explicitly the resilience of the overall system. We show that it is possible to design resilient systems with this method already in the early design stage and compare the energy efficiency and resilience of these different system designs.
To increase pressure to supply all floors of high buildings with water, booster stations, normally consisting of several parallel pumps in the basement, are used. In this work, we demonstrate the potential of a decentralized pump topology regarding energy savings in water supply systems of skyscrapers. We present an approach, based on Mixed-Integer Nonlinear Programming, that allows to choose an optimal network topology and optimal pumps from a predefined construction kit comprising different pump types. Using domain-specific scaling laws and Latin Hypercube Sampling, we generate different input sets of pump types and compare their impact on the efficiency and cost of the total system design. As a realistic application example, we consider a hotel building with 325 rooms, 12 floors and up to four pressure zones.
The paper industry is the industry with the third highest energy consumption in the European Union. Using recycled paper instead of fresh fibers for papermaking is less energy consuming and saves resources. However, adhesive contaminants in recycled paper are particularly problematic since they reduce the quality of the resulting paper-product. To remove as many contaminants and at the same time obtain as many valuable fibres as possible, fine screening systems, consisting of multiple interconnected pressure screens, are used. Choosing the best configuration is a non-trivial task: The screens can be interconnected in several ways, and suitable screen designs as well as operational parameters have to be selected. Additionally, one has to face conflicting objectives. In this paper, we present an approach for the multi-criteria optimization of pressure screen systems based on Mixed-Integer Nonlinear Programming. We specifically focus on a clear representation of the trade-off between different objectives.
Water suppliers are faced with the great challenge of achieving high-quality and, at the same time, low-cost water supply. In practice, the focus is set on the most beneficial maintenance measures and/or capacity adaptations of existing water distribution systems (WDS). Since climatic and demographic influences will pose further challenges in the future, the resilience enhancement of 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, metrics based on graph theory have been proposed. In this study, a promising approach is applied to assess the resilience of the WDS for a district in a major German City. The conducted analysis provides insight into the process of actively influencing the
resilience of 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 course Physics for Electrical Engineering is part of the curriculum of the bachelor program Electrical Engineering at University of Applied Science Aachen.
Before covid-19 the course was conducted in a rather traditional way with all parts (lecture, exercise and lab) face-to-face. This teaching approach changed fundamentally within a week when the covid-19 limitations forced all courses to distance learning. All parts of the course were transformed to pure distance learning including synchronous and asynchronous parts for the lecture, live online-sessions for the exercises and self-paced labs at home. Using these methods, the course was able to impart the required knowledge and competencies. Taking the teacher’s observations of the student’s learning behaviour and engagement, the formal and informal feedback of the students and the results of the exams into account, the new methods are evaluated with respect to effectiveness, sustainability and suitability for competence transfer. Based on this analysis strong and weak points of the concept and countermeasures to solve the weak points were identified. The analysis further leads to a sustainable teaching approach combining synchronous and asynchronous parts with self-paced learning times that can be used in a very flexible manner for different learning scenarios, pure online, hybrid (mixture of online and presence times) and pure presence teaching.
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.
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.
Component failures within water supply systems can lead to significant performance losses. One way to address these losses is the explicit anticipation of failures within the design process. We consider a water supply system for high-rise buildings, where pump failures are the most likely failure scenarios. We explicitly consider these failures within an early design stage which leads to a more resilient system, i.e., a system which is able to operate under a predefined number of arbitrary pump failures. We use a mathematical optimization approach to compute such a resilient design. This is based on a multi-stage model for topology optimization, which can be described by a system of nonlinear inequalities and integrality constraints. Such a model has to be both computationally tractable and to represent the real-world system accurately. We therefore validate the algorithmic solutions using experiments on a scaled test rig for high-rise buildings. The test rig allows for an arbitrary connection of pumps to reproduce scaled versions of booster station designs for high-rise buildings. We experimentally verify the applicability of the presented optimization model and that the proposed resilience properties are also fulfilled in real systems.
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.
One central challenge for self-driving cars is a proper path-planning. Once a trajectory has been found, the next challenge is to accurately and safely follow the precalculated path. The model-predictive controller (MPC) is a common approach for the lateral control of autonomous vehicles. The MPC uses a vehicle dynamics model to predict the future states of the vehicle for a given prediction horizon. However, in order to achieve real-time path control, the computational load is usually large, which leads to short prediction horizons. To deal with the computational load, the control algorithm can be parallelized on the graphics processing unit (GPU). In contrast to the widely used stochastic methods, in this paper we propose a deterministic approach based on grid search. Our approach focuses on systematically discovering the search area with different levels of granularity. To achieve this, we split the optimization algorithm into multiple iterations. The best sequence of each iteration is then used as an initial solution to the next iteration. The granularity increases, resulting in smooth and predictable steering angle sequences. We present a novel GPU-based algorithm and show its accuracy and realtime abilities with a number of real-world experiments.