Prof. Dr.-Ing. Ludger Overmeyer

Managing partner & Spokesperson of Management
+49 (0)511 279 76-119


The method of injection molding is one of the most important processes in the processing of plastics. Thus moldings can be produced economically in large quantities and with a high reproducibility. Besides quality the energy consumption in the production is an important part because of the energy transition and the rising energy prices. In particular, small and medium enterprises from the plastics processing industry in Germany with about 3,000 companies are, therefore, forced to optimize their processes and production equipment energetically.

injection molding, plastics processing, energy optimization, parameter optimization, energy model

Path-finding algorithms (PFA) are successfully used to find the optimal path between two locations. Good results are obtained if they are used in scenarios where the entire environment can be described mathematically. Production environments of automated guided vehicles (AGVs) are not one of those. PFA find solutions that are mathematically correct but miss human expertise that would dismiss solutions of the algorithm that aren’t applicable to a real production layout. This paper presents a hybrid algorithm consisting of an A* algorithm, and a fuzzy logic control in order to generate a fuzzy-enhanced A* algorithm (FEA*) that produces efficient and applicable road maps for AGVs. First computational results are shown.

path-finding algorithm, fuzzy-logic, expert system, agv, road maps

This paper is concerned to technology trends in logistics and shows a user interface which is focused on voice commands for using it with automated guided vehicles (AGV). Furthermore a multimodal human-machine interaction (HMI) will be presented, which gives the user the possibility to communicate and control an AGV due to information from a speech recognition system and an electroencephalograph (EEG). It will be shown, which potentials based on the merging between the acoustical voice signals and the non-invasive recording of the brainwaves from the EEG-Headset are available. By the detection of the cognitive and emotional state of the user from the signal curves by the EEG like attention or mental effort, an intelligent HMI should be realized. As a result of this, dialogues between humans and machines could be used more efficient and wrong inputs, like for example the request for a reconfirmation if an inattention is detected, could be reduced. First perceptions will be shown in this paper. In conclusion there will be a prospect of upcoming studies in the future.

driverless transport systems, driverless transport vehicles, voice control, eeg

In the context of industry 4.0 cognitive technical systems are systems that can adapt functionality flexibly and completely personalized to the specific needs of an operator or a product. Due to a wide range of intelligent sensors technical systems have the cognitive ability. In this presentation, examples of cognitive system from the intralogistics are shown.

intralogistics, cognitive system, sensor technology, industry 4.0

Designing a road layout for automated guided vehicles (AGV) can be a very laborious process that is based in big parts upon the knowledge of experienced system planers. Up until now, it isn’t possible to save that knowledge in a form that makes it usable in an automated layout process for AGV- roadmaps. The research project aims to integrate the knowledge of the system planers in an artificial intelligence, so that in the future an automated process of designing AGV roadmaps is achievable. The knowledge is implemented within a fuzzy-logic and can be used as a controller for the planning process.

automated guided vehicles, expert system, fuzzy logic, fuzzy logic controller

While definitions already exist for smaller scale device structures e. g. nanotechnology, the conceptual distinction between standard large products and large scale or XXL products is currently insufficient. This study presents a basic definition of large scale products. At first hypotheses are being derived and examined at an empirical study of three sample products threaded nuts, screw presses and passenger aircrafts. It will be shown that the transition from conventional products to XXL large scale products is characterized by a disproportionate increase in the ratio of product costs to the augmentation of a characteristic product’s feature. Based on the results a definition for the characterization of large scale products is established referring to the technical, organizational and economical restraints and to the available processes and tools.

xxl-product, large-scale, xxl, definition

The range of structure sizes for industrial products produced today is increasingly expanding. This trend is evident in both small-scale (e.g. semiconductor applications) and large-scale (e.g. wind turbine rotors) products. While definitions already exist for smaller scale device structures, the conceptual distinction between conventional large products and large scale products is currently insufficient. In this study, we present a potential basis for the definition of large scale products. To achieve this, we derive hypotheses and examine these in the context of an empirical study using the examples of several sample products. It is shown that the transition from conventional products to large scale products is characterized by a disproportionate increase in product costs due to the augmentation of a characteristic product feature. Eventually we derive a proposed definition which characterizes large scale products in the field of production engineering.

xxl-product, large-scale, xxl, definition

Unlike current production and transport systems the human being has the ability to adapt to physical changes in the workplace as well as organizational changes of the workflow. The aim of the research project " FTF out-of -the-box " is to empower fork lift trucks through cognitive technologies to autonomously handle tasks in logistic processes and execute them independently. Transport orders are given by voice and gesture control. To implement such an interactive autonomous guided vehicle ( AGV) a distributed intelligence to optimize its behavior independently and flexibly by adapting to changing production environments is needed.

driverless transport systems, cognition,production systems, flow of information, human-machine inter

Automated guided vehicle systems (AGVS) basically consist of a control station, a communication system and automated guided vehicles (AGV). Control of the AGVS has the task to carry out a transport order once it is issued by a higher level system. The transport order is implemented by the AGVS-control in an actual movement of the AGV. The number of AGV varies between a few up to 100 AGV. Due to the high number of AGV the likelihood of distraction in the route network increases. Todays central AGVS controls take into account the dynamic and evolving traffic situations inadequately and are insufficiently robust and flexible in terms of changes and disturbances .

agv, decentralzied control, automated guided vehicles

The customer-oriented individual production, as part of the future project "Industry 4.0", is based on the progressive shortening of development cycles. The parallel to the material flow directed flow of information gains in importance for a decentralized material flow control. The use of this newly available information through the production systems requires cognitive abilities on the machines. For this future machines as well as handling and transport systems should communicate, identify problems, make their own conclusions, learn and plan. For this purpose cyber physical production systems are the technological foundation.

cyber-physical production systems, individual production, intelligent networking

When designing supply chains two opposing principles must be weighed. Supply chains are either rigid and allow a high throughput, e.g. belt conveyors, or they are flexible and only allow a lower throughput,e.g. forklift trucks. Versatile supply chains, which goes beyond the flexibility present both principles with new technical and economic challenges. In the project ISI-WALK (intelligent interfaces in versatile supply chains) methods and technologies for efficient design of versatile supply chains have been developed. Based on the cognitive abilities of people and the resulting high mutability, industrial trucks should be able to recognize their surroundings, to communicate information, to conclude, learn or plan. To achieve these goals an assistance system for industrial trucks based on 3D cameras to support the store and release from stock was developed, as well as an optical positioning system for navigation.

optical positioning, active infrastructure, data transmission, signal processing, image processing

In this paper, a novel, widely usable gripper system for craneless and weather-independent assembly of rotor blades for offshore wind turbines is presented. This gripper system was developed in the context of the research project "XXL Assembly aids" of the IPH - Institute of Integrated Production Hannover gGmbH.

assembly aid, wind energy plan, xxl-products

In this article, a novel approach for an optical tracking system is presented, which is used in addition to the positioning of industrial trucks in particular the tracking and storage of the position data of carriers in intralogistics. The locating system consists of an active optical infrastructure and a receiving unit .

optical positioning system, indoor navigation

Growing XXL products reach dimensions that are no longer manageable by humans without innovative technological support. Therefore (semi-)automated assembly aids for the final assembly of large components are needed. The assembly of XXL-products is similar to the construction of prototypes. The aim is to avoid redundant new developments and designs of installation aids and to make them available across processes. In addition to presenting a method to systematize and select the right installation aid, the development of a gripper system for craneless and thus weather-independent assembly of rotor blades for offshore wind turbines is shown in this paper.

assembly aid, wind energy plan, xxl-products

In the research project "IdentOverLight" a new Auto-ID system ,using visible light communication, was developed. The new label combines the advatages of existing Auto-ID systems. It is rewriteable like RFID, machine-readable like Barcodes and readable by human like labels.

auto-id, rfid, qr-code, visible light communication

Automated guided vehicle systems (AGVS) are a vital component for efficient production systems in connection to intra logistics and essential for parts of the internal material handling, so they could not imagine living without them. The essential function of an AGVS is to control the automated guided vehicles (AGV), which are able to provide with application-specific load handling devices like telescopic forks or lifting tables, automatically. AGV could be used in different parts of applications like for example the transport of pallets, assembly or commissioning. The motivation of this project is to develop a new market for competitive autonomous transport systems. Economic forklifts should be created by technological development to handle logistical subtasks, like transferring goods, commissioning and transporting, autonomously.

driverless transport systems, driverless transport vehicles, autonomous, 3d camera technology, voice

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

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

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

The product design already determines 70% of the future product costs. Therefore, the structural design offers a promising approach for reducing the lifecycle costs of an airplane. An essential design parameter is the decision between a monolithic or modular construction. The current design of aircraft wings can be described as largely monolithic; the basic structure consists of a small number of undivided components. For example the top cover of the Airbus A350 wing consists of a single component with a length of 32m. For the production of these large scaled components production machines, e.g. autoclaves, with very huge dimensions are needed. However other aircraft parts such as the fuselage are not one-piece components. The fuselage is composed of several fuselage modules, which are pre-equipped and then riveted together. In this paper, a small-scaled modular design for airplane wings is presented and the technical feasibility is discussed. Moreover, we identified modularization factors which significantly influence the decision between a monolithic or modular construction.

structural design, large scaled products, modular design