The project REFoCh is about resource efficient forging of complex high duty parts, e.g. crankshafts. Within this project founded by the European Union, a new process chain for a crankshaft will be developed with the aim of reducing the flash quota significantly. In the conventional forging sequence, 54 % flash occur, the aimed flash quota is 15 %. To reach this objective, a multidirectional forging step will be implemented in the new process chain in order to reduce the material significantly.
flash reduced, multidirerectional forging, cranskshafts
The material costs represent up to 50 % of the total production costs. By decreasing the flash ratio the material usage and production costs in forging operations can be reduced. For complicated forging parts the development of a new forging sequence is necessary to achieve a flash reduced forging sequence. This development was performed for a two-cylinder crankshaft. The new flash reduced forging sequence is using flashless preforming operations, an induction reheating of the preformed complicated work piece and a flash reduced final forging. With the reduction of the flash ratio from 54 % down to 10 % the total energy consumption was reduced and the competitive capacity of forging SME’s is increasing.
flash reduced, process chain, crankshaft, induction heating
Data analysis on a microcontroller in the immediate vicinity of the measuring point creates an intelligent sensor node that enables a condition prognosis of gearbox components. The IPH compares different approaches of analysis regarding computing time and energy consumption in order to minimize the effort of wireless data transmission.
condition monitoring, wireless sensor nodes, microcontroller
The production ramp-up is often a critical period for manufacturing companies. It is essential to prepare an efficient plan and to monitor consistently the abidance of this plan. Generally processes and activities can be monitored with key performance indicators. This article describes an approach to identificate key performance indicators for the monitoring of additional production capacities at new locations.
production ramp-up, maturity model, aggregation logic, ramp-up management
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, the challenges regarding the production of large-scale products were presented as a major focus of current research.
xxl products, large-scale products, production technology, logistics, automation technology
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, the challenges regarding leadership within lean enterprises were presented as a major focus of current research.
lean production, lean management, leadership
The generation of road maps for automated guided vehicles (AGVs) in the area of logistics is increasing in complexity as a result of the changing production environment. Reasons for that are the shorter product life-cycles and the advances in the field of AGVs. So far, the generation of roadmaps for AGVs is a manual task and is therefore time-consuming and expensive. Information from different sources (e. g. the production layout and the transport matrix) have to be evaluated and be joined. A simplification offers the storage of expert knowledge of system planers in a form of artificial intelligence in a fuzzy-rule base. This concept is going to be realized in a software tool that is going to be able to automatically generate roadmaps for AGVs.
automated guided vehicles, expert system, fuzzy logic, fuzzy logic controller
Companies are confronted with a business environment that is becoming more and more turbulent. As a result the load spreading increases. The causing factors and what actions a company can do in order to overcome those problems are unknown. This article deals with the identification of potential influence-parameters on load scattering and their mapping in a simulation-model in order to determine the effects of these parameters on load spreading.
work load scattering, influencing factors, simulation model
Economic growth in Germany and Europe secures jobs and prosperity. However, the impacts on our environment are often negative. Because more goods are produced and the consumption increases, traffic and thus the greenhouse gas emissions rise. In order to keep these emissions as low as possible, the stated goal is to shift transport from road to rail. Thats why many terminal stations are preparing for rising turnover figures. However, the problem of maximizing throughput capacities is unsolved. To answer this question, the IPH has developed an innovative, event-discrete model used in a material flow simulation based on the software Plant Simulation.
connection station, simulation model, material flow simulation
The industrial production process is subjected to a high coordination and communication needs arising from the division of labor as a result of specialization. Trade-offs are omnipresent. For decision making the used indicators often do not have the same information base. The information-based reorganization of tasks can help here. The aim is to increase the decision quality and speed.
task allocation, information needs, organizational design, production indicators
Manufacturing companies are forced to reduce their energy costs because of rising electricity tariffs. Due to the increasing volatility of energy rates so far unused potential arises. As a sub-discipline of production planning and control the manufacturing control determines the temporal process of work orders and has great impact on the energy costs of the production. This article describes the approach of an energy cost-efficient manufacturing control, taking account of the established targets.
time-varying energy costs, fluctuating energy consumption, manufacturing control, production plannin
When designing delivery concepts, companies often have a choice between different alternatives. The decision between these alternatives is no longer made only on their costs and logistical efficiency. Rather the ecological compatibility of the processes is more and more considered. This paper introduces ways to integrate environmental sustainability into decision-making.
ecological evaluation, delivery concepts, green logistics
The overall objective of the project was to develop a method for the automated CAD modeling and costing of progressive dies. The method should firstly enable the automated creation of a CAD model of the tool based on a strip layout. The tools should be modularized and the interactions of the modules to the tool design are described in rules. The rules should then enable the automated CAD modeling. Secondly, a link of CAD models with automated costing and monitoring should be done. Basis of the costing and monitoring were the CAD models of the tool and the established standard processes in the tool production.
artificial intelligence, tool and die industry, determination of manufacturing costs, CAD-automation
The approach "Ident Over-Light" combines the positive features of existing auto-ID methods such as RFID, barcode and labels, in a new concept, whose special feature is the visible light which is used for communication with the information carrier. The information carrier is rewritable and automatically readable both for the employee in plain text as well as for an automated reading system.
auto-id, rfid, qr-code, visible light communication
A breakdown of a wind turbine entails high costs. The more reliable the prognosis of the condition of every single component is carried out, the better the maintenance can be planned. For example the maintenance could run in a time with low wind yield. Furthermore, impending breakdowns can be detected and avoided. Within the project “SteigProg” data-mining algorithms were analyzed for their ability to condition prognosis in wind turbines. An improved condition prognosis contributes a more efficient operation of wind turbines. Measurable savings result by minimizing downtimes, improved planning and shortening of maintenance operations.
condition prognosis, wind turbines
The growing dynamics in the economic environment necessitate new approaches for analyzing and influencing the dynamic behavior of production networks. Analysis of nonlinear dynamics can help to differentiate the causes of the formation of dynamics. One key cause is the production network partners’ differing responsiveness, i.e. the logistics capability to react.
supply chain design, logistics reactivity, peripheral production network, dynamic systems
