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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.
Additive manufacturing (AM) works by creating objects layer by layer in a manner similar to a 2D printer with the “printed” layers stacked on top of each other. The layer-wise manufacturing nature of AM enables fabrication of freeform geometries which cannot be fabricated using conventional manufacturing methods as a one part. Depending on how each layer is created and bonded to the adjacent layers, different AM methods have been developed. In this chapter, the basic terms, common materials, and different methods of AM are described, and their potential applications are discussed.
The implementation of IO-Link in the automation industry has increased over the years. Its main advantage is it offers a digital point-to-point plugand-play interface for any type of device or application. This simplifies the communication between devices and increases productivity with its different features like self-parametrization and maintenance. However, its complete potential is not always used.
The aim of this paper is to create an Arduino based framework for the development of generic IO-Link devices and increase its implementation for rapid prototyping. By generating the IO device description file (IODD) from a graphical user interface, and further customizable options for the device application, the end-user can intuitively develop generic IO-Link devices. The peculiarity of this framework relies on its simplicity and abstraction which allows to implement any sensor functionality and virtually connect any type of device to an IO-Link master. This work consists of the general overview of the framework, the technical background of its development and a proof of concept which demonstrates the workflow for its implementation.
Rapid Tooling
(2019)
Trotz fortschreitender Automatisierung bleiben manuelle Tätigkeiten ein wichtiger Baustein der Fertigung kundenindividueller Produkte. Um die Mitarbeiter(innen) zu unterstützen und um eine effiziente Arbeit zu ermöglichen, werden zunehmend auf Augmented Reality (AR) basierende Systeme eingesetzt. Die vorgestellte Arbeit konzentriert sich auf die Entwicklung ganzheitlicher AR-Arbeitsplätze für den Einsatz in kleinen und mittleren Unternehmen (KMU). Das entwickelte AR- Handarbeitskonzept beinhaltet eine Just-in-time-Darstellung der Arbeitsaufgaben auf Werkstücken mit automatisierter Fertigungskontrolle. Als
Reaktion auf kurze Produktlebenszyklen und hohe Produktvielfalten sind alle Komponenten auf maximale Flexibilität ausgelegt. Ein Umrüsten auf neue Produkte kann innerhalb von Minuten erfolgen.
The manufacturing share of laser powder bed fusion (L-PBF) increases in industrial application, but still many process steps are manually operated. Additionally, it is not possible to achieve tight dimensional tolerances or low surfaces roughness. Hence, a process chain has to be set up to combine additive manufacturing (AM) with further machining technologies. To achieve a continuous workpiece flow as basis for further industrialization of L-PBF, the paper presents a novel substrate system and its application on L-PBF machines and post-processing. The substrate system consists of a zero-point clamping system and a matrix-like interface of contact pins to be substantially connected to the workpiece within the L-PBF process.
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.
As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni–Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of the Monel family of alloys with Nb and high Si content is, for the first time, processed via the laser powder bed fusion process (LPBF). Being novel to the LPBF processes, optimum LPBF parameters were determined, and hardness and tensile tests were performed in as-built conditions and after heat treatment at 1000 °C. Microstructures of the as-cast and the as-built condition were compared. Highly dense samples (99.8% density) were achieved after varying hatch distance (80 µm and 140 µm) with scanning speed (550 mm/s–1500 mm/s). There was no significant difference in microhardness between varied hatch distance print sets. Microhardness of the as-built condition (247 HV0.2) exceeded the as-cast microhardness (179 HV0.2.). Tensile specimens built in vertical (V) and horizontal (H) orientations revealed degrees of anisotropy and were superior to conventionally reported figures. Post heat treatment increased ductility from 20% to 31% (V), as well as from 16% to 25% (H), while ultimate tensile strength (UTS) and yield strength (YS) were considerably reduced.
The increasing digitalization brings new opportunities but also puts new challenges to modern industrial systems. Software agents are one of the key technologies towards self-optimizing factories and are currently used to address the needs of cyber-physical production systems (CPPS). However their interplay in industrial settings needs to be understood better.This paper focusses on securing a cloud infrastructure for multi-agent systems for industrial sites. An industrial site contains multiple production processes that need to communicate with each other and each physical resource is abstracted with a software agent. This volatile architecture needs to be managed and protected from manipulation. The proposed infrastructure presents a security concept for TCP/IP communication between agents, machines, and external networks. It is based on open-source software and tested on a three-node edge cloud controlling a model-plant.
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.