620 Ingenieurwissenschaften und Maschinenbau
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Plasmonics and nanophotonics both deal with the interaction of light with structures of typically sub-wavelength size in one of more dimensions. Over the past decade or two, interest in these topics has grown significantly. This includes basic research towards detailed understanding of light-matter interaction and the manipulation of light on the nanometer scale as well as the search for applications ranging from quantum information processing, data storage, solar cells, spectroscopy and microscopy to (bio-)sensors and biomedical devices. Key enablers for this development are advanced materials and the variety of techniques to structure them with nanometer precision on the one hand, and progress in the theoretical description and numerical implementations, on the other. Besides the traditional metals Au, Ag, Al, and Cu also compounds such as refractory metal nitrides with much higher durability as well as semiconductors, dielectrics and hybrid structures have become of interest. Structuring techniques are not only aiming at the fabrication of individual elements with highest precision for detailed interaction analysis, but also at methods for large scale, low-cost nanofabrication mostly for sensor applications. In the former case, mostly electron beam lithography and focused ion beam milling are employed, while for high throughput various forms of nanoimprint and self-assembly based techniques are favored. Thin film deposition and pattern transfer techniques are mostly derived from those developed for nano-electronics, however more recently methods such as electroless plating, atomic layer deposition or etching and 3-D additive techniques are appearing. Thus, highly specialized expertise has been acquired in the different disciplines, and successful research and technology transfer will draw from this pool of knowledge.
The general conclusion of climate change studies is the necessity of eliminating net CO2 emissions in general and from the electric power systems in particular by 2050. The share of renewable energy is increasing worldwide, but due to the intermittent nature of wind and solar power, a lack of system flexibility is already hampering the further integration of renewable energy in some countries. In this study, we analyze if and how combinations of carbon pricing and power-to-gas (PtG) generation in the form of green power-to-hydrogen followed by methanation (which we refer to as PtG throughout) using captured CO2 emissions can provide transitions to deep decarbonization of energy systems. To this end, we focus on the economics of deep decarbonization of the European electricity system with the help of an energy system model. In different scenario analyses, we find that a CO2 price of 160 €/t (by 2050) is on its own not sufficient to decarbonize the electricity sector, but that a CO2 price path of 125 (by 2040) up to 160 €/t (by 2050), combined with PtG technologies, can lead to an economically feasible decarbonization of the European electricity system by 2050. These results are robust to higher than anticipated PtG costs.
Employing diffuse reflection ultraviolet visible (UV–Vis) spectroscopy we developed an approach that is capable to quantitatively determine flux residues on a technical copper surface. The technical copper surface was soldered with a no-clean flux system of organic acids. By a post-solder cleaning step with different cleaning parameters, various levels of residues were produced. The surface was quantitatively and qualitatively characterized using X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), Fourier transform infrared spectroscopy (FTIR) and diffuse reflection UV–Vis spectroscopy. With the use of a multivariate analysis (MVA) we examined the UV–Vis data to create a correlation to the carbon content on the surface. The UV–Vis data could be discriminated for all groups by their level of organic residues. Combined with XPS the data were evaluated by a partial least squares (PLS) regression to establish a model. Based on this predictive model, the carbon content was calculated with an absolute error of 2.7 at.%. Due to the high correlation of predictive model, the easy-to-use measurement and the evaluation by multivariate analysis the developed method seems suitable for an online monitoring system. With this system, flux residues can be detected in a manufacturing cleaning process of technical surfaces after soldering.
This paper covers test and verification of a forecast-based Monte Carlo algorithm for an optimized, demand-oriented operation of combined heat and power (CHP) units using the hardware-in-the-loop approach. For this purpose, the optimization algorithm was implemented at a test bench at Reutlingen University for controlling a CHP unit in combination with a thermal energy storage, both in real hardware. In detail, the hardware-in-the-loop tests are intended to reveal the effects of demand forecasting accuracy, the impact of thermal energy storage capacity and the influence of load profiles on demand-oriented operation of CHP units. In addition, the paper focuses on the evaluation of the content of energy in the thermal energy storage under practical conditions. It is shown that a 5-layer model allows to determine the energy stored quite accurately, which is verified by experimental results. The hardware-in-the-loop tests disclose that demand forecasting accuracies, especially electricity demand forecasting, as well as load profiles strongly impact the potential for CHP electricity utilization on-site in demand-oriented mode. Moreover, it is shown that a larger effective capacity of the thermal energy storage positively affects demand-oriented operation. In the hardware-in-the-loop tests, the fraction of electricity generated by the CHP unit utilized on-site could thus be increased by a maximum of 27% compared to heat-led operation, which is still the most common modus operandi of small-scale CHP plants. Hence, the hardware-in-the-loop tests were adequate to prove the significant impact of the proposed algorithm for optimization of demand-oriented operation of CHP units.
Rapidly changing market conditions and global competition are leading to an increasing complexity of logistics systems and require innovative approaches with respect to the organisation and control of these systems. In scientific research, concepts of autonomously controlled logistics systems show a promising approach to meet the increasing requirements for flexible and efficient order processing. In this context, this work aims to introduce a system that is able to adjust order processing dynamically, and optimise intralogistics transportation regarding various generic intralogistics target criteria. The logistics system under consideration consists of various means of transport for autonomous decision-making and fulfilment of transport orders with defined source-sink relationships. The context of this work is set by introducing the Learning Factory Werk 150 with its existing hardware and software infrastructure and its defined target figures to measure the performance of the system. Specifically, the important target figures cost and performance are considered for the transportation system. The core idea of the system’s logic is to solve the problem of order allocation to specific means of transport by linking a Genetic Algorithm with a Multi-Agent System. The implementation of the developed system is described in an application scenario at the learning factory.
Learning factories can complement each other by training different competencies in the field of digitalisation and Industry 4.0. They depict diverse sections of the product development process and focus on various technologies. Within the framework of the International Association of Learning Factories (IALF), the operating organisations of learning factories exchange information on research, training and education. One of the aims is to develop joint projects. The article presents different concepts of cooperation between learning factories while focusing on the improvement of the development of learners competencies e.g. with a broader range of topics. A concept of a joint course between the learning factories in Bochum, Reutlingen and Darmstadt is explained in detail. The three learning factories will be examined with regard to their similarities and differences. The joint course focuses on the target group of students and the topic of digitalisation in the development and production of products. The course and its contents are explained in detail. The new learning approach is evaluated on the basis of feedback from the participants. Finally, challenges resulting from the cooperation between learning factories at different locations and with different operating models will be discussed.
Development work within an experimental environment, in which certain properties are investigated and optimized, requires many test runs and is therefore often associated with long execution times, costs and risks. This can affect product, material and technology development in industry and research. New digital driver technologies offer the possibility to automate complex manual work steps in a cost-effective way, to increase the relevance of the results and to accelerate the processes many times over. In this context, this article presents a low-cost, modular and open-source machine vision system for test execution and evaluates it on the basis of a real industrial application. For this purpose a methodology for the automated execution of the load intervals, the process documentation and for the evaluation of the generated data by means of machine learning to classify wear levels. The software and the mechanical structure are designed to be adaptable to different conditions, components and for a variety of tasks in industry and research. The mechanical structure is required for tracking the test object and represents a motion platform with independent positioning by machine vision operators or machine learning. An evaluation of the state of the test object is performed by the transfer learning after the initial documentation run. The manual procedure for classifying the visually recorded data on the state of the test object is described for the training material. This leads to an increased resource efficiency on the material as well as on the personnel side since on the one hand the significance of the tests performed is increased by the continuous documentation and on the other hand the responsible experts can be assigned time efficiently. The presence and know-how of the experts are therefore only required for defined and decisive events during the execution of the experiments. Furthermore, the generated data are suitable for later use as an additional source of data for predictive maintenance of the developed object.
Digitalization changes the manufacturing dramatically. In regard of employees’ demands, global trends and the technological vision of future factories, automotive manufacturing faces a huge number of diverse challenges. Currently, research focuses on technological aspects of future factories in terms of digitalization. New ways of work and new organizational models for future factories have not been described yet. There are assumptions on how to develop the organization of work in a future factory but up to now, literature shows deficits in scientifically substantiated answers in this research area. Consequently, the objective of this paper is to present an approach on a work organization design for automotive Industry 4.0 manufacturing. Future requirements were analyzed and deducted to criteria that determine future agile organization design. These criteria were then transformed into functional mechanisms, which define the approach for shopfloor organization design
The use of learning factories for education in maintenance concepts is limited, despite the important role maintenance plays in the effective operation of organizational assets. A training programme in a learning factory environment is presented where a combination of gamification, classroom training and learning factory applications is used to introduce students to the concepts of maintenance plan development, asset failure characteristics and the costs associated with maintenance decision-making. The programme included a practical task to develop a maintenance plan for different advanced manufacturing machines in a learning factory setting. The programme stretched over a four-day period and demonstrated how learning factories can be effectively utilized to teach management related concepts in an interdisciplinary team context, where participants had no, or very limited, previous exposure to these concepts.
Development of an easy teaching and simulation solution for an autonomous mobile robot system
(2019)
With mass customized production becoming the mainstream, industries are shifting from large-scale manufacturing to flexible and customized production of small batch sizes. Agile manufacturing strategies adopted by SMEs are driving the usage of collaborative robots in today's factories. Major challenges in the adoption of cobots in the industry are the lack of a highly trained workforce to program the robot to perform complex tasks and integration of robot systems to other smart devices in the factory. In addition, the teaching and simulation by non-robotics experts of many industrial collaborative robot systems like the KUKA LBR iiwa is a major challenge, since these systems are designed to be programmed by robot experts and not by shop floor workers or other non-experts. This paper describes the research and development activities done for reducing the barriers in operation and ensure holistic integration of LBR iiwa cobot in the assembly on the example of the ESB Logistics Learning Factory. These include a visual programming solution for the easy teaching of various tasks. Robotic tasts are classified based on common robotics applications and application-specific blocks abstracting specific actions are implemented. A factory worker with no programming competency cour create robot programs by combining these blocks using a Graphical User Interface. In addition, a simulation solution was developed to visualized, analyse, and optimize robotic workflow before deployment. an autonomous mobile robot is integrated with the LBR iiw to improve reconfigurability and thus also the productivity. The system as a whole is controlled using an event-driven distributed control system. Finally, the capabilities of the system are analysed based on the design principles of Industrie 4.0 and potential future research ideas are discussed to further improve the system.