As a result of increasing globalization in procurement an increased competition exists for production companies. In the field of sheet metal forming companies will therefore be required to produce proper quality products with short delivery times at high punctuality at lowest possible production costs.
sheet metal forming, experience recovery, equipment effectiveness
In a current research project at IPH – Institut für Integrierte Produktion Hannover gGmbH and Laser Zentrum Hannover e. V. the knowledge of die failure mechanisms during the forming of aluminium will be extended. Aspects of the analysis are minimization, quantification and forecasting of adhesion. Furthermore it will be analysed in what way the tools, laser-dispersed with aluminium oxide, decrease the adhesion.
aluminium forging, wear, wear coatings
The German forging industry is under ever increasing pressure to develop innovative products at low prices. The design of logistic efficient forging processes regarding economic aspects is an opportunity for cost reduction. Thereby, sumultaneous consideration of technological interfaces as well as indirect processes (e.g. tool logistics) leads to a continuous process chain optimization. Logistic effects of resulting process changes have to be identified within a dynamic production controlling system in order zu improve the logistic performance.
logistical optimization, process chain optimisation, production planning and -steering
The planning and configuration of cyclically interlinked production systems, which are for example used for assembly of electric motors, is often carried out under great time pressure in the bidding phase. Data mining methods allow a high time saving approach in tender preparation. Based on this technology, the IPH developed a software to shorten the planning time and to improve the planning results.
interlinked production systems, planning, characteristic curves, data mining
This paper presents the application of radio frequency identification (RFID) as an electronic authenticity certificate for pharmaceutical packaging along the pharmaceutical supply chain. It focuses on the one hand on the assurance of the supply chain to protect against plagiarism and on the other hand on the production of an electronically secured packaging. In order to realize a secured packaging, a RFID-transponder is integrated in the folded box. The data saved on the RFID-chip is inseparably connected with the folded box.
product protection, rfid, identification technologies, folding boxes, antenna printing
This lecture presents the application of radio frequency identification (RFID) as an electronic authenticity certificate for pharmaceutical packaging along the pharmaceutical supply chain. It focuses on the one hand on the assurance of the supply chain to protect against plagiarism and on the other hand on the production of an electronically secured packaging. In order to realize a secured packaging, a RFID-transponder is integrated in the folded box. The data saved on the RFID-chip is inseparably connected with the folded box.
product protection, rfid, identification technologies, folding boxes, antenna printing
This lecture presents the IPH and introduces its topics. In particular, research projects and cooperation opportunities are addressed.
software development, production research
Increasingly, purchasing decisions for equipment are determined by the offered service and suppliers are changed in order to dissatisfaction with the service. But service quality and efficiency can already be increased in the hotline of the manufacturer. Two research institutes in Hannover are currently developing a software system based on semantic similarity search of service cases.
semantic search, similarity search, service
Most companies have different production logistic strategies. In practive, the control of them is very difficult. Therefore, a manual is developed.
production logistics, control of productions strategies, key performance indicators
For identification of requirements of tasks and objectives in the state of the art of logistic controlling of small and medium-sized companies (SMCs), the IPH have carried out a study. In this study, the results are categorized in propagation, focuses and development needs.
study, logistic-controlling, production logistics
Design and configuration of model-based rules. Disruptions in production with negative impact on the objectives of production logistics need to be identified and resolved. Small and medium sizes enterprises (SMEs) often lack of sufficient human capital to control the logistic relations in production and thus to realize a targeted improvement of a logistic process. Moreover, a profound knowledge about the complex relations between logistic objectives and measures against interferences in production is often missing. The missing knowledge of coherences may explain why aspired logistic objectives in SMEs are often not achied. This article introduces an approach for diagnosing interferences in production logistics and deriving recommendations for measures using an assistance system developed at the IPH - Institute of Integrated Production Hannover gGmbH.
assistence system, objectives of production logistics, diagnose of interruptions in production
A functional logistic strategy for production logistics may be deduced from a corporate strategy in order to ensure competitiveness. The challenge is to monitor the strategic guidelines by appropriate key data. When the monitoring identifies divergences, a diagnosis helps to derive measures at the operational level in order to ensure stable or improved processes. The paper introduces a rule-based expert system to help master these challenges. The approach is based on the production logistic objectives (low work in process level, short throughput time, high schedule reliability and high utilization) with their key indicators. In a problem solving tree, those key indicators are connected with further significant diagnostic key data, according to their cause-effect relationships. The expert system rules are based on the fundamental laws of production logistics by Wiendahl and Nyhuis. A diagnostic procedure for production logistics will be triggered by quality control charts in an expert system.
knowledge management in production and logistics, ict for manufacturing and logistics, intelligent,
During the utilization phase, sheet fabricating tools cause up to 70% of their own life cycle costs. In general, they may now be procured only on the basis of their purchase price. IPH - Institute of Integrated Production Hannover gGmbH has developed a method which can predict and consider the life cycle costs based on knowledge of these tools during the planning process.
calculation, life cycle costs, tool manufacturing
Up to the present day, literature has already dealt with stockout-costs, but methods to quantify these costs have not been developed until now. The absence of these kinds of methods prevents an efficient logistic positioning between stockout-costs and the costs for holding safety-stocks. The costs for safety-stocks in a warehouse to provide a desired service-level can already be determined, but the stockout-costs connected with a desired service-level cannot be quantified yet. This article introduces a mathematical function to quantify the costs in a company’s production caused by missing material, depending on the amount of missing material and its missing time.
stockout costs, material shortage, service-level, logistic costs, warehouse costs
Next generation wind turbines are to be built higher and higher. As a result of the stronger and more regular wind in greater altitudes, more energy gain can be achieved by rising hub heights of wind turbines. However, the risk of tower failure rises with tower height and mass.
xxl-product, large-scale, xxl, wind turbine, wind power, lightweight construction, tower constructio
The challenges of integrating the welding process into the sheet metal working tool are handling the emissions and associated pollutions of the tool as well as creating a reliable monitoring-system for the welding-process. Within the scope of a research project, a reliable technology for the integration of condenser discharge (CD) stud welding with tip ignition was developed and tested. It complements existing solutions for integrated resistance welding processes. Due to its high-speed capability, low insertion of energy and high process reliability, this technique is particularly suitable for the integration in sheet metal working tools. A newly developed exhaustion-system is installed and tested for the first time. The new technology produced top quality CD arc stud welding along with high process stability and robustness in long-term tests.
sheet metal, capacitor discharge arc stud welding, cd arc stud welding, tip ignition, follow-on tool
In standard sheet metal forming processes the subsequent welding is executed outside the forming press. Because of that spatial separation complex handling and transferring operations are being required which result in a deterioration of the joint accuracy. The challenges of integrating the welding process into the sheet metal working tool are handling the emissions and associated pollutions of the tool as well as creating a reliable monitoring-system for the welding-process. Within the scope of a research project, a reliable technology for the integration of condenser discharge (CD) stud welding with tip ignition was developed and tested. Due to its high-speed capability, low insertion of energy and high process reliability, this technique is particularly suitable for the integration in sheet metal working tools. The new technology produced top quality CD arc stud welding along with high process stability and robustness in long-term tests.
sheet metal, capacitor discharge arc stud welding, cd arc stud welding, tip ignition, follow-on tool
While merely solutions for integrated resistance welding have been known until now, a tool technology in a reliable process for the functional integration of initial contact capacitor discharge (CD) arc stud welding was developed in a research project. This technology is particularly well-suited to integration into sheet metal working tools, amongst other reasons, because of its high joining speed, low energy input and high process reliability. In endurance tests, this new technology can be used in order to manufacture high-quality stud welds with a high robustness to disturbing variables at the same time, not least due to the fact that the extraction of welding spatter was tried out for the first time.
sheet metal, capacitor discharge arc stud welding, cd arc stud welding, tip ignition, follow-on tool
To realise integration, a new modular tool concept was developed in a research project. However, negative process effects like weld splatters occur. As a counteraction the control of process parameters, an extraction system and mechanical solutions were developed. Focus of this research project was to demonstrate process stability and reachable numbers of strokes. Welding tests with a developed joining step within a progressive die showed good joining results and high process stability. Welded studs were examined by reverse bending experiments and achieved maximum values pointing to the sheet material were used. Disturbances were introduced reliably detected by process monitoring of the voltage and current curve progression as well as the bolt movement. The analysis of the measurements showed the robustness of the automated welding process. Welding emissions were efficiently removed by suction from the shielded welding area in the tool without compromising on joining qualities.
sheet metal, capacitor discharge arc stud welding, cd arc stud welding, tip ignition, follow-on tool
Having new potential applications in forging processes in mind, composites of an ordered mesoporous carbon and luminescent metal phosphate nanocrystals were synthesized for the first time. Three kinds of CMK-3/CePO4:Tb nanocomposites were prepared by treating a mesoporous CMK-3 host with different lanthanide phosphate precursor solutions. Various tests showed that in two cases the nanocrystals were located inside the mesopores, whereas in the third case the nanocystals merely adhered to the outer surfaces of the carbon particles. A preliminary evaluation of the lubrication properties of the CMK-3 and one nanocomposite material was performed. The friction factors determined by means of ring upsetting tests revealed that the carbon materials were able to lower frictional forces although they were 3–4 times less efficient than a commercial graphite-based reference lubricant.
lubricant, forging, cmk-3, cepo4:tb, mesoporous carbon, nanocomposites
