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 offer a sufficient trade-off between accuracy, range, and costs. Based on optical technologieswe a novel 4-degree-of-freedom (4-DOF) positioning system is presented 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.
optical positioning, active infrastructure, data transmission, signal processing, image processing
Timely and simultaneous material supply for the final assembly stage of complex machinery and equipment is a logistical challenge. Performing poorly in this task leads to delayed shipments to customers and high amounts of capital are committed in incomplete sets of supply materials. There is no need for expensive software if data quality and the disposition processes are examined carefully enough to identify possible ways to improve the situation.
material supply, disposition procedures, supply processes, capital commitment, inventory costs, logi
For a systematic complaint handling the 8D method has been established. However, so far there are no adequate measurement and evaluation techniques to assess the quality of an 8D report. As a consequence it can not be guaranteed at any time that the complaint processing is carried out correctly and efficiently. In a research project of the FQS, the Institute of Metal Forming (IFUM) and the IPH - Institute of Integrated Production gGmbH an automated metric system for measuring and evaluating the quality of 8D reports was developed. To determine the metrics algorithms are used for text mining. Also manual reviews are used to realize the required range of reviews efficiently and reliably.
8d-report, claims management, complaint, quality management
This paper describes the development of a warm cross wedge rolling process with one area reduction. The paper also includes results of finite element analysis (FEA), experimental trials with a downsized work piece and the adaption to the industrial work piece in original size. In the FEA simulations tools with serrations on the side have been used. The downsizing method is explained and the difference between FEA, downsized and originally sized work piece with the focus on forming forces, temperature distribution and defects are presented.
warm forging, cross wedge rolliing
A suitable technology for pre-forming of highly loaded forgings is the cross-wedge rolling. With little effort, investigations are now carried out using a new module for cross-wedge-rolling with flat dies. To expand the existing geometric limitation of warm forged steel components, the cross-wedge-rolling at temperatures between 650 °C and 950 °C was investigated. In addition, first studies with aluminum using the new module are described.
warm forging, cross-wedge-rolling
In flashless precision forging the punch moves in the cavity after die closing. Thus, the material is distributed until complete form filling. Using a new developed forging tool, parts can be pierced within the forging operation. In this tool concept the punch goes through the entire thickness of the part. By the upper punch the excess material is pressed as far down as the workpiece is completely pierced. To test this tool concept on its practicality, forging experiments were carried out on a screw press.
forging, flashless, precision, piercing
The early detection of defects in forged parts offers economical advantages due to the possibility of sorting them out of the process chain. The aim of the presented research project is the development of a forging process monitoring without sensors. In the process electric current is flowing through the forged part. The quality of the forged parts is measured by the electrical signal. Typical defects of forgings like underfilling and wrong temperature of the billet show characteristic signals and therefore can be detected. These parts are sorted out of the process chain. The user of the forging machine is able to adjust the forging process immediately.
forging, process monitoring
The implementation of process monitoring technologies in manufacturing processes allows significant cost and time savings. An online process monitoring of die cavity filling in warm forging processes could not be realized until now. Important process parameters for example billet volume, billet temperature or lubrication could only be observed after forging. This paper describes the implementation of an online process monitoring system based on electricity.
forging, process monitoring
To produce preforms for complex long flat parts with an unsteady mass distribution along the longitudinal axis rolling processes, like cross wedge rolling, can be used. Tools for cross wedge rolling processes can be constructed as roller or flat, both with wedges. In the collaborative research project "SFB 489 - Process chain for the production of precision forged high performance parts" the subproject "Innovative machine and tool technology for precision forging" deals with the development of a flashless forging process for a two cylinder crankshaft with pin and flange. This process is developed by IPH - Institut für Integrierte Produktion Hannover. The first preform of the developed forging sequence is produced by a cross wedge rolling process on the basis of flat with wedges. To consider the mass distribution of the two cylinder crankshaft in the preform for a rolling process four mass concentrations for the crank arms and mass concentrations for pin and flange are needed.
crankshaft, cross wedge rolling (CWR), forging sequence, preform, rolling process
Lightweight design of cars is one way to reduce fuel consumption and increase the range of cars. This is an important factor to attain the EU limit values for CO2 emissions for vehicles and thus to avoid penalties for exceeding these limits as of the year 2012. The growing number of uses for high-strength steels or lightweight structures are adequate means to reduce weight. At IPH - Institut für Integrierte Produktion Hannover gGmbH a method to produce hollow profiles made of aluminum was developed. This method, called hydroforging, combines flashless forging and tube hydroforming. It allows the production of thick-walled hollow aluminum profiles with undercuts without the need for complex tool kinematics. The forging is supported by an active medium. A tool concept has been developed using the drives of a hydraulic press with die cushion. With this tool, various part geometries shall be produced and analyzed. To produce the tools' interior pressure and the forming pressure, liquid tin as an incompressible active medium is used. The forming is initiated by upsetting the aluminum profiles and supported by the active medium, so that the profile is pushed against the cavity of the dies. The process was designed based on simulations and will be verified by practical experiments. This paper describes the development of the forging process with an active medium.
hydroforming, forging, tubes, aluminium, FEA
This paper discusses the influence of circadian performance fluctuations on workers conducting manual assembly tasks under consideration of biorhythm. A data analysis method statistically verifies the correlations between performance fluctuations and investigated biorhythm. Finally, the paper suggests different areas of practical application of the confirmed performance fluctuations (e.g. shift work, cycle time adjustment).
performance efficiency fluctuation, assembly, industrial work system, data analysis method
This paper discusses the different characteristics used to describe XXL-Products and, furthermore represents fundamental aspects concerning the construction (eg. principles, methods) of production systems. A survey of experts at XXL-Producers is used to identify the most commonly used production systems. The article demonstrates the survey results and finally concludes with an outlook on further actions.
lean-production-methods, production system, xxl-products
In order to obtain high logistical performance in a production network at low logistical costs, there has to be a high level of synchronization in the material provision of the final assembly. The level of synchronization can be restrained by dynamic effects in a network. This paper presents an approach for identifying critical material procurement processes that are accountable for an insufficient achievement of logistical goals in the material provision. In addition, the results of a simulation study are explained that analyzes the effects of measurements conducted to increase the synchronization of the material provision by also taking dynamic effects into account.
dynamics, material provision, production networks, production planning and control (ppc)
Many small and medium enterprises (SMEs) miss their logistics objectives. In science and practice there is a growing recognition that the problems of production planning and control (PPC) cannot be solved only by the development and use of software tools. PPC systems usually have limited degrees of freedom for carrying out the tasks given to the employee. Many methods of PPC systems have the potential of influencing the behavior and performance of employees. The development of a logistics-oriented incentive system can support the logistical goal achievement of SME. Aligning incentives on operational logistics objectives anchors the objectives in the employees’ personal consciousness and everyday commitment the employees’ actions to support the logistics performance on the production level.
controlling, logsitic performance indicators, incentive system,
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 8D report-based complaint management were presented as a major focus of current research.
quality management, complaint management, 8d report, data mining, text mining
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 implementation of lean production were presented as a major focus of current research.
production system, lean production, expert system, knowledge management, data mining
To meet the growing demand for energy, further developments are necessary in the field of renewable energies. In two research projects, engineers of IPH - Institut für Integrierte Produktion Hannover have investigated how to increase the efficiency of wind turbines.
xxl products, large-scale products, wind turbines, data mining
The performance in logistics is vitally important for Companies. However the achievement of logistics objectives is deflating in practice. A possible reason are divergent employee and company interests, which constrict an efficient order processing. Once more employees are in focus in research and practice. How to resolve these differences in employee and company interests to enhance logistics? The Incentive System which is developed by IFA and IPH in Hannover provides solutions for an effective support of logistic objectives.
incentive system, logistics, divergent employee and company interests
Warm forged parts have advantages in comparison to conventional hot forged parts: Closer tolerance, reduced surface roughness, no scale and reduced decarburization. However, the geometrical spectrum of warm forged parts is restricted by high flow stress. To overcome this geometrical limitation, new rolling and forging processes have been developed in the Seventh framework programme EU in research project “DeVaPro – Development of a Variable Warm Forging Process Chain”. In the focus is layout of warm preforming operation by cross wedge rolling followed by an intermediate heating and warm final forming in conventional dies. In this paper results of initial experimental tests and results of application of warm cross wedge rolling are shown.
shrinkage compensation, fem
The aim is the development of a function-based method to support the planning of offerings in injection molding. It is assumed that tools and shapes are unique items, but the tools’ functions are recurrent. Possible post-calculations are captured and can be used better for the calculation of offerings via the function-based calculation. Methods of similarity search assist in prediction and precise determination of manufacturing expense of a tool. In order of the validation of the concept by real data the software-demonstrator is linked to existent post-calculation tools and transferred conceptually to further unique products.
function-based method, tender preparation, injection molding
