Logistics is an essential part of the value chain. Therefore, sustainable logistics systems are a decisive competitive and success factor for companies. Through individual customer requirements, shorter innovation cycles and an increasing variety of product types, the requirements have become increasingly complex in the material handling engineering sectors. To meet these requirements and to allow a continuous increase in efficiency of logistics systems, the development of innovative systems is necessary. A key to the design of such systems is the use of optical technologies. Using a simplified scenario the possibilities of optical technologies in intralogistics are represented in this paper.
materials handling, optical communication, optics, intralogistics
In the research project ISI-WALK methods and technologies for the efficient design and economical operation of supply chains have been developed. These methods and technologies are helping to enable logistic systems to adept to different materials and information flows. On the basis of the the human cognitive abilities and the resulting high mutability logistic systems shall be enabled to recognize their surroundings, to communicate relevant information and to learn or plan autonomously. The technical results are divided into four sub-goals: a system based on 3D camera technology assistance system for trucks, a system for optical position detection in industrial environments, a versatile coordinate-based warehouse management system and a method for planning and evaluation of the major driving forces. The research project was funded within the framework concept "Research for the industry of tomorrow" by the Federal Ministry of Education and Research (BMBF).
optical positioning, active infrastructure, data transmission, signal processing, image processing
In general, XXL-Products consist of many different parts which are often individually produced using various manufacturing technologies. Companies collaborate in production networks while focusing on their core competencies. In order to realize an evaluation and improvement of the network’s logistical maturity level and thus the logistical efficiency, a maturity-level-based development guideline is needed.
supply chain management, supplier evaluation, production networks, logistical performance, maturity
Innovative developments often result from the knowledge generated in the lifecycle of existing products. Following this approach in a current research project engineers of IPH develop methods and tools for the acquisition and utilization of knowledge from the entire product lifecycle.
product lifecycle, knowledge management
A central control of automated guided vehicle systems (AGVS) doesn’t longer satisfy the require-ments of a versatile production. With procedures from the field of artificial intelligence a control can be decentralized and made more flexible. In this way the tasks of the central control can be distributed to different entities in the system. Thus the complexity of the tasks is reduced. The present article deals with the decentralization of the AGVS control and focuses on the order allocation, route finding and conflict resolution.
agv, decentralzied control, automated guided vehicles
Recent research dealt with the basic forgeability of aluminium-matrix composites produced under laboratory conditions. These research projects concentrated on metallurgy and, by deriving flow curves, on formability. In contrast to laboratory conditions, the industrial use requires large batches of raw materials and takes place under real conditions. Those conditions have not yet been analysed. This paper describes the combination of mechanical advantages of aluminium-matrix composites and a flashless forging process. The advantages can be outlined as higher part strength, compared to conventional forging parts with the same weight. Newly derived flow curves demonstrate formability and were used to evaluate basic forging parameters. The first forging trials in a conventional forging process using a high forging rate resulted in broken parts and therefore required a reduced deformation rate. The matrix slug material provides a higher deformation rate but has to be reduced, due to the use of MMCs. Using a conventional forging press (e.g. screw press) causes material failures likes cracks, because forging Al-MMCs requires a reduced forming speed of 20 mm/s. Reducing the forming speed, hydraulic presses are recommended. FE-analysis of the newly developed flashless forging process is described and depicts the basic forming operations (spreading, elongating and climbing) of the material in the forging die. Altogether a new strategy for a flashless forging process layout with Al-MMC is shown.
forging, flashless, aluminium, matrix, composite, characterization, upsetting, FEA, simulation, tool
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 planing of adaptable factories were presented as a major focus of current research.
research and development, factory layout planning, resource efficiency, adaptability
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 planing of adaptable factories were presented as a major focus of current research.
research and development, factory layout planning, resource efficiency, adaptability
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 planing of adaptable factories were presented as a major focus of current research.
factory layout planning, practical use case, adaptability
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.
research and development, xxl products, large-scale products, production technology, logistics, auto
The design of the delivery concept represents a decisive competitive factor for companies, since this significantly affects the throughput time and inventory levels. This paper explains how environmental issues can be quantified in addition to the conventional types of costs and presents a method for the selection and design of a delivery concept.
ecological costs, delivery concepts, logistics costs, procurement
Indoor positioning is an enabling technology for advanced intra-logistic applications that employ tracking and tracing of goods and vehicles. For these applications, a positioning technology must otTer a sufficient trade-off between accuracy, range, and costs. In this paper we present a novel positioning system based on optical technologies that is designed for tracing vehicles in a logistic environment. The major innovations of the system are an active optical infrastructure allowing absolute positioning without any other data source, and, on the receiver side, a hybrid data processing approach that combines signal and image processing. Using these optical technologies, a high accuracy can be achieved at lower costs compared to other approaches. The static positioning error is below 0.1 m. The active optical positioning approach joins signal and image processing technologies to a low-cost and high accuracy system. While designed for intra-logistic applications the technology can be adopted other fields such as building and shop-floor navigation.
active infrastructure, data transmission, signal processing, image processing
With automated guided vehicle systems (AGVs) a trend toward intelligent, distributed systems is emerging . Here, the so-called agent technology, originally from the field of artificial intelligence play an important role. Agents are autonomous entities that make the basis of predetermined rules independent decisions. Tasks in a AGV system such as the award of transport orders or the pathfinding, can be realized by certain patterns of behavior of the agents. Together with the IPH - Institute of Integrated Production Hannover scientists of the OFFIS develop an overall concept for the decentralized self-regulation of AGV systems.
agv, decentralzied control, automated guided vehicles
In automotive industry, parts made of aluminum alloys are used with increasing frequency. During forging operations for the production of aluminum long flat pieces, defects like folds can appear. Especially internal folds are of interest, which are only evident in the fiber orientation and have a negative effect on the dynamic mechanical properties of the forged part. In forging, the forming operation can be realized either from one direction (uni-directional) or from several directions (multi-directional). The boundary conditions for multi-directional forging are described in this article. For a given tool geometry, multi-directional forging permits the realization of fold-free forgings, which has been shown to be not possible with uni-directional operations. A newly developed method based on Finite-Elements-Analysis (FEA) simulation helps with the design of the forming process and the determination of the appropriate tool geometry. A new algorithm integrates the computer-aided identification of internal folds. For a given process and tool geometry, the area with internal folds is adjusted, until the simulation shows no fold formation. It is shown, that by using this model, a dependable assessment and correction of forging tools and forming process and thus the realization of a fold-free forming are possible.
multi-directional forging, aluminum forging, internal folds, finite-elements-analysis, algorithm, to
In 2022 germanys last nuclear power plants will be shut down. In addition to the decision to phase out nuclear power a worldwide shortage of fossil fuels will lead to a steady rise in energy costs. Therefore the IPH develops procedures and methods, which will help companies to reduce their energy costs.
energy costs, occupancy plan, energy consumption
This paper presents the development of methods and rules for an automated CAD model building and cost calculation of tools. Starting with the strip layout of the product to be manufactured, tool models are configured and their components linked to production processes and cost data. By using artificial intelligence algorithms, the experience of the employees is taken into account for tender preparation.
tool making, tool shop, quotation costing, data mining, expert system
A smart option to increase the energy yield of wind turbine generators is to increase its height. There is an exponential increase of the usable wind energy at enlarging the tower’s height, but also an exponential increase of the tower’s weight. The application of lightweight design concepts in the production of wind turbine tower sections may lead to weight reduction while keeping the tower’s stiffness at an equal level. Here the results of a study for lightweight concepts and their implementation on towers and a guiding systematic approach are being presented. The investigated design solutions proved successfully in bionic, aerospace and automotive applications. FEA simulations were used to compare the different structures and to estimate their feasibility. The investigation’s main result is a lightweight structure which provides weight reductions up to 20 %, by using lower wall thicknesses.
forging, genetic algorithm, preforming optimization
In order to achieve higher energy yields of wind turbine generator, the most expedient approach is to enlarge the tower height. By increasing the height the usable wind energy increases exponentially, but also does the tower weight. Therefore in a research study several constructional designs for lightweight tower design have been investigated. The design considered several design solutions which proved successfully in bionic, aerospace and automotive applications. FEA simulations were used to compare different structures and to estimate their feasibility. The best-fit identified constructional design is based on trapezoidal sheet. The developed design enables a weight reduction up to 20 % in comparison to standard towers.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
A smart option to increase the energy yield of wind turbine generators is to increase its height. There is an exponential increase of the usable wind energy at enlarging the tower’s height, but also an exponential increase of the tower’s weight. The application of lightweight design concepts in the production of wind turbine tower sections may lead to weight reduction while keeping the tower’s stiffness at an equal level. Here the results of a study for lightweight concepts and their implementation on towers and a guiding systematic approach are being presented. The investigated design solutions proved successfully in bionic, aerospace and automotive applications. FEA simulations were used to compare the different structures and to estimate their feasibility. The investigation’s main result is a lightweight structure which provides weight reductions up to 20 %, by using lower wall thicknesses.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
The approach "Ident Over Light" combines the positive features of the existing Auto-ID process in a new concept which is based on visible light. The information carrier is rewritable and automatically readable both for the employee in plain text as well as for an automated reading system .
visible light communication
