Publications

The development of an ecological logistical impact model for the holistic consideration of the logistics performance should allow companies and especially SMEs to be able to record the CO2 emissions of the logistics transparently. For the development of such a model, the basic influencing factors must be defined and furthermore established as quantitatively assessable criteria. This paper discusses the basic relationships between logistics and ecology. Moreover, the boundaries for an ecological and logistical impact model are discussed and procedures for the definition of the required evaluation criteria are described.

Ecology, Logistics, CO2 calculation, Impact Modell, sustainabilty

A hot forging process allows to produce parts of excellent quality and technical properties. Nevertheless, it is not possible to forge undercut geometries like piston pin bores, it is usually necessary to manufacture them in subsequent processes. Thus, an undercut-forging process was newly developed. Such a process requires a multidirectional forming tool, which is challenging due to a high clamping force of the tool during the process. With the research results, the requirements to the crucial tool components of heavy springs diminish, allowing using standard spring devices instead of large and expensive custom designed devices. The aim of this study is to analyze the clamping force, its origin, and influencing factors in order to facilitate the tool design. Therefore, in forming simulations the input parameters press velocity, initial temperature, and punch shape were investigated, and their effect on the clamping force was statistically evaluated. The press velocity has the major impact on the resulting clamping force. The initial part temperature and the shape of the punch tool showed minor but still significant effects. This combination of input parameters reduces the load and the stress on the tool, enabling to perform the process on smaller forging presses. Eventually, forging trials validated the results.

forging, undercut, FEA, multidirectional, clamping force, tool design

The article deals with the development of an automated 2D- and 3D-layout-acquistion technology. For that purpose, a semi-autonomous UAV is to be used, to acquire 2D- or 3D-aerial images. An automated stitching or mapping algorithm can match the images together and create a scale image of the factory layout. The automation will also be able to interpret the scanned layout, e.g. detection and measurement of different functional areas. The acquired data can directly be used for factory planning, e.g. creating digital 3D-images or physical 3D-printed images.

drone, threedimensional factory layout, object recognition in point clouds, factory planning

Future factory planning projects are much easier and cheaper than today. With a drone it es possible to scan a factory layout during the flight in a short time. To achieve this benefits, researchers of the IPH are developing a new factory planning method.

drone, threedimensional factory layout, object recognition in point clouds, factory planning

Rotary energy harvesters offer the possibility of generating energy in the center of rotation or outside of the center of rotation. There are both concepts with reference to the outer housing as well as different concepts without a fixed reference. In addition, Energy Harvester solutions are available that provide energy to the housing and generate energy through the rotation of the shaft. The selection of a concept must be made individually for each application and depends on various influencing factors. Decisive in particular are the installation space, the energy requirement of the sensor node and the speed.

energy supply for microsystems, energy harvesting, rotary energy harvester, power management

Currently used methods for factory layout planning are limited in their evaluation methods. Factory evaluation is either qualitative or quantitative, but limited to a few objectives. These deficits were overcome by the development of a quantitative, multidimensional ad hoc factory evaluation method. On this basis, it is now possible to develop a method for factory layout planning that reduces the planning effort and significantly increases the quality of the solution.

facility layout planning, factory planning, operations research, mathematical modelling

For companies it is challenging to identify application scenarios for Industry 4.0 as well as to use the associated potential. This article describes a strategy, which includes methodical and knowledge-based guidelines for decisions, to increase the likelihood of beneficial industry 4.0 transformations.

industry 4.0, strategy, production system

In forging industry, the development of new bulk metal forming technologies still is determined by a separation between construction and simulation. The resulting iterations take a lot of time. In this paper, the data mining method neuronal network is used to predict the forming force of a finite element forging simulation of a flange.

simulation, AI, prognosis, forming force

In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving composite hybrid forging has been developed. In this process, an aluminum solid part and a steel sheet were formed in a single step and joined at the same time with zinc as brazing material. For this purpose, the zinc was applied by hot dipping on the aluminum in order to produce a connection via this layer in a forming process, under pressure and heat. Due to the formed intermediate layer of zinc, the formation of the Fe-Al intermetallic phases and the contact corrosion are excluded. By determining the mathematical relationships between joining parameters and the connection properties the strength of a specific joint geometry could be adjusted to reach the level of conventional joining techniques. In addition to the presentation of the joint properties, the influence of the joining process on the structure of the involved materials is also shown. Furthermore, the failure behavior under static tensile and shear stress will be shown.

lightweight construction, aluminum, joining properties

The measurement of the absolute rotational angle and torque via sensors forms the basis for many industrial sectors. Until now, combined sensors have not been available, so that a lot of installation space is occupied by sensor setups. In addition, the sensor setups get expensive quickly. Therefore, an optical and non-contact measurement method to detect the absolute angle of rotation and torque was developed. This paper presents the validation methodology, the setup of the test bench and the validation results. With an angular resolution of 0.001 degree and an accuracy of more than 0.05 percent, the results are promising. However, for industrial application further investigations on determining torque and miniaturizing the optical setup are required.

absolute angular position, angle difference, sensor, torque

In this paper, the investigation of thin flash generation in precision forging process of an aluminum long flat part is described. The aim was to derive a predictive simulation method for thin flash generation in order to increase both process and part quality in the future. The forging processes were varied by use of different preforms with equal volumes but different mass distributions while using the same final part geometry. The experimentally forged parts were analyzed concerning the amount and part area of the generated thin flash. The conducted FE simulations were analyzed concerning the hydrostatic pressure values p in the part areas near to the tool gap between upper and lower die immediately before form-filling. For a more detailed comparison, single p values were included to hydrostatic pressure functions P. The comparison between the P functions and the experimentally determined thin flash height shows, that high pressure values as well as high gradients of the P functions indicate less thin flash generation. The method therefore allows a qualitative prediction of thin flash generation. It can provide two kind of information. First: The prediction of the specific locations where thin flash is likely to occur in one final part by use of one single preform. Second: The qualitative prediction of the specific final part areas were thin flash is likely to occur depending on different preform geometries. This method will decreases the necessity of time-consuming forging trials and can shorten the preform designing process in the future.

forging flashless precision forging FEA aluminum predictive simulation method

Rising and increasingly volatile energy prices resulting from increased power feeds from renewable sources such as solar and wind energy are confronting manufacturers with new challenges. If these companies procure their power supplies at ?uctuating short-term prices from electricity exchanges or through energy purchasing pools, they can in?uence the result-ing energy costs through production control via its actuating variables while energy consumption remains constant. A form of sequencing that decides at short notice which order will be processed next shows particularly high potential. The energy price-oriented sequencing rule that is introduced in this article prioritises orders with a high energy requirement at times when energy prices are low and gives precedence to orders that require less energy at times when energy prices are high, without neglecting the scheduled completion deadline. However, this sequencing rule can only be applied e?ectively under certain preconditions. These are elaborated in this article by means of a simulation study that will con?rm the way the rule functions.

production planning and control, manufacturing control, sequencing, energy costs

In the forging industry, like in many other economic sectors, it is common to simulate forming processes before executing experimental trials. An iterative simulation process is more economic than trials only but still takes a lot of time. A simulation with realistic parameters takes many hours. For an economical production the idea of predicting some main results of the simulation by Data mining was developed. Within this paper, the use of four different Data mining methods for the prediction of certain characteristics of a simulated flange forging process are presented. The methods artificial neural network, support vector machine, linear regression and polynomial regression are used to predict forming forces and the lack of volume. Both are important parameters for a successful simulation of a forging process. Regarding both, forging forming forces and lack of volume after the simulation, it is revealed that an artificial neural network is the most suitable.

data mining, artificial neural network, linear and polynomial regression, support vector machine

Interactive assistance systems such as data glasses or headsets as a new human-machine interface enable an increase in process quality and speed through networking within the factory. However, small and medium-sized enterprises (SMEs) are critical to the implementation of these systems. Therefore, this article describes the development of a maturity model for a systematic ability analysis and increase to the implementation of interactive assistance.

industry 4.0, interactive assistance systems, maturity models, implementation support

This paper describes the production process of serially arranged hybrid steel parts, produced by combining a laser welding process with a subsequent cross wedge rolling process. The presented results are only a first approach in order to get first insights in the forming behaviour of laser welded and cross wedge rolled parts. The investigated material combination is C22 (1.0402) and 20MnCr5 (1.7147). This innovative process chain enables the production of hybrid parts. To evaluate the developed process chain, the weld and the joining zone is analysed before and after cross wedge rolling. Main results are that the joining process using laser welding enables a strong bonding between the two materials with a higher hardness in the joining zone than for the individual materials. After the forming process, the bonding of the joining zone is still present, while the hardness decreased but remains higher than of the materials themselves.

tailored forming, laser welding, hybrid parts, cross wedge rolling

The storage planning is an important component of the factory planning and describes an improvement potential in the times of an increasing global competition. The selection of a suitable storage, commissioning and transport system is a big challenge especially for small and medium-sized enterprises. In a research project of IPH – Institut für Integrierte Produktion Hannover a method for companies will be created to determine the necessary level of versatility and automation to choose an optimal system. This article introduces the research project and explains the approach and first results.

storage planning, sct systems, versatility, automation, software demonstrator

Energy requirements of belt conveyor systems are essentially determined by the necessary drive power, which is composed of the main drive and intermediate drives. The use of driven support rollers reduces the load on the conventional drive at the head of conveyor systems. Thus, the drive can be build smaller, which can lead to energy and cost savings. In contrast to conventional head drives, driven rollers enable the implementation of modular conveyor systems. The theoretical possibilities and consequences of driven rollers are promising. Due to a lack of knowledge regarding the economic efficiency and behavior under certain conditions, driven rollers have not yet been integrated into real operation. In order to investigate the behavior of driven rollers and to ensure the introduction into practice, test stands are indispensable. This paper presents the concept of driven rollers and, on this basis, the development of a test stand for investigating these rollers.

driven roller, test rig, belt conveyor, energy efficiency

To forge a flashless crankshaft within few steps and with low energy consumption innovative forging processes are necessary, such as cross wedge rolling and multi-directional forging. The direct combination of the two forming processes normally leads to flash at the bottom of the crankweb preform after the multi-directional forging. The reason for the flash generation is the rotation-symmetric cross wedge rolled billet, which is formed laterally to the main axis during multi-directional forging. In this paper, a parameter field in which flashless crankshaft preforms can be forged is presented. The parameters varied within the experimental research are the forming angle and the cross section area reduction at cross wedge rolling as well as the axis offset, the billet temperature and the forming velocity at the multi-directional forging. The limits of this flashless parameter field are shown in several diagrams. For a flashless combination of two forming process low values for all parameters such as a forming angle of 30°, a cross section area reduction of 30 %, and a billet temperature of 1050 °C are recommended. Furthermore, the intensity of the influence of the significant parameters are shown. The cross section area reduction thereby caused the highest range at flash generation with 0.4 mm.

multi-directional forging, cross wedge rolling, crankshaft, parameter study, flashless

The melting process in an aluminum melting furnace cannot be monitored by contact sensors, since the furnace is not accessible due to the high temperatures (more than 700 °C). Therefore, monitoring the melting process by means of optical sensors is investigated for the first time in this research project. This article deals with an innovative optical measuring system that is able to monitor the melting bridge despite the red-hot furnace walls. For this purpose, a light-field camera is installed on top an aluminum melting furnace in order to monitor the process and to control a targeted heat input into the melting furnace using a rotatable burner. The light-field camera used can capture a 3D point cloud with only one image. To achieve this, a separate field of lenses is placed between the image sensor and the main lens, projecting a virtual intermediate image onto the actual image sensor for further data processing. In addition, a self-developed image analysis program serves to monitor the height variation of the aluminum block and any melting rest on the melting bridge of the furnace.

Thus, the energy efficiency of the aluminum melting process could be increased by 15 % and the melting time reduced by almost 20 minutes by means of online monitoring.

light-field camera, process monitoring, image processing, melting process, energy efficiency

One aim of the research project "Networked cognitive production Systems (netkoPs)" was the development of the formal language Production Modeling Language (PML). The PML is to be understood as a digital twin of the product and the production system. At the beginning, useful potentials for PML from the current state of research as well as the aims of the research project netkoPs were derived. Afterwards, based on a requirement analysis, the required data fields for the PML were classified. In a next step, the PML, based on the AutomationML, was implemented. The potential benefits formulated in the context of netkoPs could finally be demonstrated in connection with the further research results. For example, a preliminary ProductPML can equipping the machine before the product arrives.

digital twin, ProductionML, decentralized control, material flow

Your contact person