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
Today most technical parts and components are made of monolithic materials. Nevertheless, the previously used monolithic materials reach their technological and constructive limits, so that an improvement of the component properties can be realized by hybrid parts. Forging of previously joined semi-finished products to net shape hybrid components is a promising method to produce functional adapted parts in a few process steps. This new process chain offers a number of advantages compared to other manufacturing technologies. Examples are the production of specific load-adapted forging parts with a high level of material utilization, an improvement of the joining zone caused by the followed forming process and an easy to implement joining process because of the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, which are produced by a combination of a deposition welding process with a subsequent hot forging (upsetting) or cross-wedge-rolling. It could be shown that the innovative process chain enables the production of hybrid parts whereby the forging processes lead to an improvement of the mechanical properties of the laser deposited material.
process chain, deposition welding, hot forging, cross-wedge-rolling
The production of large-scaled products is often associated not only with great challenges, but also with enormous costs. The way how the product is designed offers the greatest potential for cost reduction. At the IPH, engineers are currently developing a new modular design for XXL products.
xxl products, modular design
Within the research project "Intelligente Schmiedewerkzeuge zur Fehlerreduktion in der Massivumformung" (AiF 17009 N) intelligent forging tools and a specific software were developed which allow an identification of forged errors and a mold filling monitoring. This article presents the underlying concept and the developed software.
forging, process monitoring
Planning in a multi-site, non-mass production environment is a special challenge because of several sources of uncertainty. Unlike in mass production facilities, in our setting the current state is not easily and exactly known when the case of re-planning occurs. The planning procedure has to contribute to that fact, as well as to further uncertainties concerning the effects of a plan when evaluating the plan. Thus in this work, we apply online simulation as means for re-planning multi-site production in the case of resource failure. This work is a first step where two alternatives are considered when a resource fails: either wait for repair of the resource, or transport another instance of this resource from another site, if there is more than one available. Our study shows that the planning using online simulation is superior to a static strategy such as 'always wait for repair' or 'always import resource' in case of resource failure.
assembly control, simulation, production planning and control, failure management
The energy costs‘s share in the total is increasing in producing companies. Due to variations in the energy consumption over the day, arising power peaks lead to high energy costs. Power peaks could be reduced by load management systems. But these systems could have a negative impact on logistic performance figures. A simultaneous optimization of logistic performance figures and the energy consumption is not available yet. In this article a method for the energy cost-based production scheduling is presented. This method schedules jobs on machines in a way that the energy consumption is equalized and the logistic performance (makespan, stock, job delays, workload) is ensured.
energy costs, power peaks, production scheduling
The energy costs‘s share in the total is increasing in producing companies. Due to variations in the energy consumption over the day, arising power peaks lead to high energy costs. Power peaks could be reduced by load management systems. But these systems could have a negative impact on logistic performance figures. A simultaneous optimization of logistic performance figures and the energy consumption is not available yet. In this article a method for the energy cost-based production scheduling is presented. This method schedules jobs on machines in a way that the energy consumption is equalized and the logistic performance (makespan, stock, job delays, workload) is ensured.
energy costs, power peaks, production scheduling
The energy costs‘s share in the total is increasing in producing companies. Due to variations in the energy consumption over the day, arising power peaks lead to high energy costs. Power peaks could be reduced by load management systems. But these systems could have a negative impact on logistic performance figures. A simultaneous optimization of logistic performance figures and the energy consumption is not available yet. In this article a method for the energy cost-based production scheduling is presented. This method schedules jobs on machines in a way that the energy consumption is equalized and the logistic performance (makespan, stock, job delays, workload) is ensured.
energy costs, power peaks, production scheduling
The usable wind energy increases exponentially by increasing the height of wind turbine generators. The material requirements and the tower weight increases disproportionately high by growing tower height. In current designs, the height of towers is limited. The application of lightweight design concepts in the production of wind turbine tower sections can lead to a reduction in the weight with the same tower stiffness. Therefore lightweight designs have great potential to increase wind turbine efficiency. In this paper, the results of the research for lightweight concepts and their implementation on towers and a guiding systematic approach are presented. As part of the research, design concepts have been developed. These design concepts allow the mass reduction, with constant stiffness, for the wind turbine towers on land (onshore). Several investigation loops of these lightweight designs were run. Different concepts of bionics, aviation, aerospace and automotive have been investigated for their suitability in wind turbine towers. A suitable concept was identified based on trapezoidal sheets. Using these sheets, the weight of towers can be reduced by 20 %.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
At the Institut für Integrierte Produktion Hannover gGmbH (IPH) a method is currently being developed, that supports the controlling of logistical targets and associated logistics costs in the supply chain for the assembly of wind energy plants. The considered supply chain comprises all steps from the production of the individual components up to the handover to the customer. The method enables continuous prediction whether date variances have a critical monetary and scheduling impact on the project success.
material provisioning, site assembly, cost controlling, schedule deviation, early warning system, fo
Indoor positioning is the backbone of many advanced intra-logistic applications. As opposed to unified outdoor satellite positioning systems, there are many different technical approaches to indoor positioning. Depending on the application, there are different trade-offs between accuracy, range, and costs. In this paper we present a new concept for a 4-degree-of-freedom (4-DOF) positioning system to be used for vehicle tracing in a logistic facility. The system employs optical data transmission between active infrastructure and receiver devices. Compared to existing systems, these optical technologies promise to achieve better accuracy at lower costs. We will introduce the positioning algorithm and an experimental setup of the system.
optical indoor positioning, data transmission, signal processing, image processing, flexible warehou
In multi-site assembly, problems such as defective tools often cause delays. In order to avoid deferred deliveries and increased costs, assembly control is required to promptly determine a new assembly plan. A research project aims to develop a software support system which assists assembly control in the replanning process by applying online simulation to quickly identify possible plan alterations and evaluate their expected impact on logistical key figures.
assembly control, simulation, production planning and control, failure management
In this paper the development of the new production technology hybrid forging is described. Hybrid forging combines forming of bulk and sheet metal-elements including joining. Using three model experiments the joining by material bond and by form closure is analyzed. The form closure works like a riveting and the experiments showed good results. But not in every area of the specimen a material bond was present.
hybrid, forging, sheet metal forming, joining technology, steel, adhesive bond
The strength/density ratio of aluminium can be increased significantly by the integration of ceramic particles in the metal matrix, so called Aluminum MMC. Because machining of MMCs is very expensive due to the high hardness of the ceramic particles precision forging of Aluminum MMCs allows the high quantity production of near net shape components with a strength/density ration. The paper describes the development of a precision forging sequence for a demonstration made of Aluminum MMC.
aluminium metal matrix composites, flashless forging, FEA
In a research project by the Institut für Integrierte Produktion Hannover (IPH) and the Institute of Metal Forming Siegen the basics for hydroforming titanium tubes were investigated. The aim of this research project was to develop a multi-stage process chain for hydroformed parts made of titanium. First the method-specific material properties as well as the tribological system were examined. The results were combined in a simulation model which enabled the process development. Finally, the developed process chain was successfully tested using a real component and the trials were compared with the simulation results.
hydroforming, FEA, titanium
Due to high mechanical loads the die cavity shows high wear in warm forging processes. Within this paper the ability of a hydrogenated amorphous carbon doped by 40 % chromium as wear protective coating for bulk forming processes will be analysed. Therefore billets with temperatures between 650 and 1200 °C have been forged on this layer. Thereafter the layers are analysed and the wear behaviour is evaluated.
coating, forging, forming
The early detection of defects in forged parts offers economical advantages due to the possibility of sorting them out of the process chain. The detection of defects during the forging process is not state of the art. Due to the rough conditions in forging (e. g. high temperatures and forces) the integration of sensors monitoring the forging process is hardly viable. Usually defects of forged parts – which are not obvious and can therefore hardly be identified by the press user – are detected by measurements after cooling or later by the customer. In both variants costs occur. Within the presented research project an in-situ forging process monitoring is developed which works without sensors and shows results directly after forging.
metal, steel, metal processing, forging, quality
