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Production planning and control are characterized by unplanned events or so-called turbulences. Turbulences can be external, originating outside the company (e.g., delayed delivery by a supplier), or internal, originating within the company (e.g., failures of production and intralogistics resources). Turbulences can have far reaching consequences for companies and their customers, such as delivery delays due to process delays. For target-optimized handling of turbulences in production, forecasting methods incorporating process data in combination with the use of existing flexibility corridors of flexible production systems offer great potential. Probabilistic, data-driven forecasting methods allow determining the corresponding probabilities of potential turbulences. However, a parallel application of different forecasting methods is required to identify an appropriate one for the specific application. This requires a large database, which often is unavailable and, therefore, must be created first. A simulation-based approach to generate synthetic data is used and validated to create the necessary database of input parameters for the prediction of internal turbulences. To this end, a minimal system for conducting simulation experiments on turbulence scenarios was developed and implemented. A multi-method simulation of the minimal system synthetically generates the required process data, using agent-based modeling for the autonomously controlled system elements and event-based modeling for the stochastic turbulence events. Based on this generated synthetic data and the variation of the input parameters in the forecast, a comparative study of data-driven probabilistic forecasting methods was conducted using a data analytics tool. Forecasting methods of different types (including regression, Bayesian models, nonlinear models, decision trees, ensemble, deep learning) were analyzed in terms of prediction quality, standard deviation, and computation time. This resulted in the identification ofappropriate forecasting methods, and required input parameters for the considered turbulences.
The market for indoor positioning systems for a variety of applications has grown strongly in recent years. A wide range of systems is available, varying considerably in terms of accuracy, price and technology used. The suitability of the systems is highly dependent on the intended application. This paper presents a concept to use a single low-cost PTZ camera in combination with fiducial markers for indoor position and orientation determination. The intended use case is to capture a plant layout consisting of position, orientation and unique identity of individual facilities. Important factors to consider for the selection of a camera have been identified and the transformation of the marker pose in camera coordinates into a selectable plant coordinate system is described. The concept is illustrated by an exemplary practical implementation and its results.
In the past, plant layouts were regarded as highly static structures. With increasing internal and external factors causing turbulence in operations, it has become more necessary for companies to adapt to new conditions in order to maintain optimal performance. One possible way for such an adaptation is the adjustment of the plant layout by rearranging the individual facilities within the plant. Since the information about the plant layout is considered as master data and changes have a considerable impact on interconnected processes in production, it is essential that this data remains accurate and up-to-date. This paper presents a novel approach to create a digital shadow of the plant layout, which allows the actual state of the physical layout to be continuously represented in virtual space. To capture the spatial positions and orientations of the individual facilities, a pan-tilt-zoom camera in combination with fiducial markers is used. With the help of a prototypically implemented system, the real plant layout was captured and converted into different data formats for further use in exemplary external software systems. This enabled the automatic updating of the plant layout for simulation, analysis and routing tasks in a case study and showed the benefits of using the proposed system for layout capturing in terms of accuracy and effort reduction.
Supply chains have evolved into dynamic, interconnected supply networks, which increases the complexity of achieving end-to-end traceability of object flows and their experienced events. With its capability to ensure a secure, transparent, and immutable environment without relying on a trusted third party, the emerging blockchain technology shows strong potential to enable end-to-end traceability in such complex multitiered supply networks. However, as the dissertation’s systematic literature review reveals, the currently available blockchain-based traceability solutions lack the ability to map object-related supply chain events holistically, which involves mapping objects’ creation and deletion, aggregation and disaggregation, transformation, and transaction. Therefore, this dissertation proposes a novel blockchain-based traceability architecture that integrates governance and token concepts to overcome the limitations of existing architectures. While the governance concept manages the supply chain structure on an application level, the token concept includes all functions to conduct object-related supply chain events. For this to be possible, this dissertation’s token concept introduces token ‘blueprints’, which allow clients to group tokens into different types, where tokens of the same type are non-fungible. Furthermore, blueprints can include minting conditions, which are, for example, necessary when mapping assembly or delivery processes. In addition, the token concept contains logic for reflecting all conducted object-related events in an integrated token history. This ultimately leads to end-to-end traceability of tokens and their physical or abstract representatives on the blockchain. For validation purposes, this dissertation implements the architecture’s components and their update and request relationships in code and proves its applicability based on the Ethereum blockchain. Finally, this dissertation provides a scenario-based evaluation based on two industrial case studies from a manufacturing and logistics perspective to validate the architecture’s capabilities when applied in real-world industrial settings. The proposed blockchain-based traceability architecture thus covers all object-related supply chain events derived from the two industrial case studies and therefore proves its general-purpose end-to-end traceability capabilities of object flows.
UV hyperspectral imaging (225 nm–410 nm) was used to identify and quantify the honey- dew content of real cotton samples. Honeydew contamination causes losses of millions of dollars annually. This study presents the implementation and application of UV hyperspectral imaging as a non-destructive, high-resolution, and fast imaging modality. For this novel approach, a reference sample set, which consists of sugar and protein solutions that were adapted to honeydew, was set-up. In total, 21 samples with different amounts of added sugars/proteins were measured to calculate multivariate models at each pixel of a hyperspectral image to predict and classify the amount of sugar and honeydew. The principal component analysis models (PCA) enabled a general differentiation between different concentrations of sugar and honeydew. A partial least squares regression (PLS-R) model was built based on the cotton samples soaked in different sugar and protein concentrations. The result showed a reliable performance with R2cv = 0.80 and low RMSECV = 0.01 g for the valida- tion. The PLS-R reference model was able to predict the honeydew content laterally resolved in grams on real cotton samples for each pixel with light, strong, and very strong honeydew contaminations. Therefore, inline UV hyperspectral imaging combined with chemometric models can be an effective tool in the future for the quality control of industrial processing of cotton fibers.
Werkzeugmaschinen sind im Bereich des Maschinen- und Anlagenbau die größte Branche, mit denen auch in Unternehmen anderer Bereiche (z. B. Automobilbau, Aerospace) wesentliche Teile der Bruttowertschöpfung stattfinden. (Destatis, 2022) Das dynamische Verhalten von Werkzeugmaschinen beeinflusst in entscheidendem Maße die Produktivität der Produktionsanlage und die Qualität der darauf erzeugten Werkstücke. Sowohl fremderregte Schwingungen (z. B. Unwucht, Pulsation, periodisch schwankende Prozesskräfte) als auch selbsterregte Schwingungen (z. B. Rattern) führen zu schlechter Qualität der gefertigten Bauteile. Das dynamische Verhalten vonWerkzeugmaschinen wird durch die Masse, Dämpfung und Steifigkeit der einzelnen Komponenten (z. B. Maschinenbett, Ständer, Schlitten) als auch der im Kraftfluss liegenden Fügestellen (z. B. Führungen, Antriebe) beeinflusst. In diesem Beitrag werden die Auswirkungen von konstruktiven Modifikationen der Dämpfung in Gestellbauteilen bezüglich des dynamischen Verhaltens an der Zerspanstelle näher beleuchtet.
We present the results of an extensive characterization of the performance and stability of a third-order continuous-time delta-sigma modulator with active coefficient error compensation. Using our previously published coefficient tuning technique, process variation induced R-C time-constant (TC) errors in the forward signal path can be compensated indirectly using continuously tunable DACs in the feedback path. To validate our technique experimentally with a range of real TC variations, we designed a modulator with discretely configurable integration capacitor arrays in a 0.35-μm CMOS process. We configured the capacitors of the fabricated device for a range of total TC variations from -28.4 % to +19.3 % and measured the signal-to-noise ratio (SNR) as a function of the input amplitude before and after compensating the variations electrically using the feedback DACs. The results show that our tuning technique is capable of restoring the desired nominal modulator performance over the entire parameter variation range, including the system’s nominal maximum stable amplitude (MSA).
We address the problem of 3D face recognition based on either 3D sensor data, or on a 3D face reconstructed from a 2D face image. We focus on 3D shape representation in terms of a mesh of surface normal vectors. The first contribution of this work is an evaluation of eight different 3D face representations and their multiple combinations. An important contribution of the study is the proposed implementation, which allows these representations to be computed directly from 3D meshes, instead of point clouds. This enhances their computational efficiency. Motivated by the results of the comparative evaluation, we propose a 3D face shape descriptor, named Evolutional Normal Maps, that assimilates and optimises a subset of six of these approaches. The proposed shape descriptor can be modified and tuned to suit different tasks. It is used as input for a deep convolutional network for 3D face recognition. An extensive experimental evaluation using the Bosphorus 3D Face, CASIA 3D Face and JNU-3D Face datasets shows that, compared to the state of the art methods, the proposed approach is better in terms of both computational cost and recognition accuracy.
Verteilnetzbetreiber müssen verschiedene Maßnahmen ergreifen, um den Herausforderungen der zunehmenden Installation dezentraler Erzeugungsanlagen zu begegnen. Die meisten dieser Maßnahmen führen zwar zur Einhaltung der Spannungsgrenzwerte, sie läsen jedoch nicht das Problem der Rückspeisung in die überlagerte Netzebene und die damit verbundenen Leistungsverluste. Im Projekt „Demo-rONT-Alternative“ wurde ein Prototyp für einen fernsteuerbaren Kabelverteiler entwickelt, um die Trennstellenverschiebung automatisiert durchführen zu können.
The replacement of conventional material with recyclates affects product personality, particularly regarding sustainability aspects influencing consumer behaviour. A definition of personality for products made of recyclates is missing in literature. As these products require appropriate aesthetics based on material origin to communicate the advantage concerning sustainability, there is a need for research in this regard. This paper aims to develop an adequate personality of a reusable water bottle made of ocean plastic by collecting personality traits that evoke associations related to the material's origin and sustainability. We conducted two quantitative field studies. Study 1 collected associated visual perceived attributes and context-related personality traits in order to develop and visualize a preliminary design. Study 2 evaluated the design regarding associated personality traits. The overall outcome was a product personality scale consisting of 23 items plus a concrete design recommendation for a water bottle made of recycled ocean plastic. The assessment of degree of sustainability was strongly influenced by participants’ associations with personal use, familiarity with usage and the factor of stability and resilience.
Der Erfolg der Energiewende in Deutschland setzt eine zunehmende Anzahl an dezentralen elektrischen Erzeugungsanlagen (EZA) voraus. Diese dezentralen EZA, wie Photovoltaikanlagen oder Blockheizkraftwerke, bringen für Verteilnetzbetreiber große Herausforderungen mit sich. Im Rahmen des geförderten Forschungsprojekts „Demonstrator Automatisierte Kabelverteil (KV) als Alternative zum regelbaren Ortsnetztransformator (DEMO rONT-Alternative)“ wurde ein neuer Ansatz für die Lösung der bestehenden Problematik erforscht. Dieser besteht in der aktiven Änderung der Topologie der Netzgebiete je nach elektrischer Last und PV-Einspeisung (Trennstellenverlagerung).
Sleep is essential to physical and mental health. However, the traditional approach to sleep analysis—polysomnography (PSG)—is intrusive and expensive. Therefore, there is great interest in the development of non-contact, non-invasive, and non-intrusive sleep monitoring systems and technologies that can reliably and accurately measure cardiorespiratory parameters with minimal impact on the patient. This has led to the development of other relevant approaches, which are characterised, for example, by the fact that they allow greater freedom of movement and do not require direct contact with the body, i.e., they are non-contact. This systematic review discusses the relevant methods and technologies for non-contact monitoring of cardiorespiratory activity during sleep. Taking into account the current state of the art in non-intrusive technologies, we can identify the methods of non-intrusive monitoring of cardiac and respiratory activity, the technologies and types of sensors used, and the possible physiological parameters available for analysis. To do this, we conducted a literature review and summarised current research on the use of non-contact technologies for non-intrusive monitoring of cardiac and respiratory activity. The inclusion and exclusion criteria for the selection of publications were established prior to the start of the search. Publications were assessed using one main question and several specific questions. We obtained 3774 unique articles from four literature databases (Web of Science, IEEE Xplore, PubMed, and Scopus) and checked them for relevance, resulting in 54 articles that were analysed in a structured way using terminology. The result was 15 different types of sensors and devices (e.g., radar, temperature sensors, motion sensors, cameras) that can be installed in hospital wards and departments or in the environment. The ability to detect heart rate, respiratory rate, and sleep disorders such as apnoea was among the characteristics examined to investigate the overall effectiveness of the systems and technologies considered for cardiorespiratory monitoring. In addition, the advantages and disadvantages of the considered systems and technologies were identified by answering the identified research questions. The results obtained allow us to determine the current trends and the vector of development of medical technologies in sleep medicine for future researchers and research.
Sleep disorders can impact daily life, affecting physical, emotional, and cognitive well-being. Due to the time-consuming, highly obtrusive, and expensive nature of using the standard approaches such as polysomnography, it is of great interest to develop a noninvasive and unobtrusive in-home sleep monitoring system that can reliably and accurately measure cardiorespiratory parameters while causing minimal discomfort to the user’s sleep. We developed a low-cost Out of Center Sleep Testing (OCST) system with low complexity to measure cardiorespiratory parameters. We tested and validated two force-sensitive resistor strip sensors under the bed mattress covering the thoracic and abdominal regions. Twenty subjects were recruited, including 12 males and 8 females. The ballistocardiogram signal was processed using the 4th smooth level of the discrete wavelet transform and the 2nd order of the Butterworth bandpass filter to measure the heart rate and respiration rate, respectively. We reached a total error (concerning the reference sensors) of 3.24 beats per minute and 2.32 rates for heart rate and respiration rate, respectively. For males and females, heart rate errors were 3.47 and 2.68, and respiration rate errors were 2.32 and 2.33, respectively. We developed and verified the reliability and applicability of the system. It showed a minor dependency on sleeping positions, one of the major cumbersome sleep measurements. We identified the sensor under the thoracic region as the optimal configuration for cardiorespiratory measurement. Although testing the system with healthy subjects and regular patterns of cardiorespiratory parameters showed promising results, further investigation is required with the bandwidth frequency and validation of the system with larger groups of subjects, including patients.
Supply chains have evolved into dynamic, interconnected supply networks, which increases the complexity of achieving end-to-end traceability of object flows and their experienced events. With its capability of ensuring a secure, transparent, and immutable environment without relying on a trusted third party, the emerging blockchain technology shows strong potential to enable end-to-end traceability in such complex multitiered supply networks. This paper aims to overcome the limitations of existing blockchain-based traceability architectures regarding their object-related event mapping ability, which involves mapping the creation and deletion of objects, their aggregation and disaggregation, transformation, and transaction, in one holistic architecture. Therefore, this paper proposes a novel ‘blueprint-based’ token concept, which allows clients to group tokens into different types, where tokens of the same type are non-fungible. Furthermore, blueprints can include minting conditions, which, for example, are necessary when mapping assembly processes. In addition, the token concept contains logic for reflecting all conducted object-related events in an integrated token history. Finally, for validation purposes, this article implements the architecture’s components in code and proves its applicability based on the Ethereum blockchain. As a result, the proposed blockchain-based traceability architecture covers all object-related supply chain events and proves its general-purpose end-to-end traceability capabilities of object flows.
Der ›AM Field Guide‹ gibt einen ersten strukturierten Überblick in die komplexe und vielschichtige Welt der additiven Fertigungsverfahren. Getrennt nach den Materialien Polymere, Metalle und weitere Materialien werden die gängigsten jeweils auf dem Markt angebotenen AM-Verfahren schematisch dargestellt und der Verfahrenskern in Kurzform beschrieben. Neben den hier dargestellten Hauptverfahren gibt es viele Derivate und Sonderverfahren, die ebenfalls ein gesetzt werden jedoch nicht explizit gezeigt sind. Zu beachten ist, dass in dem jungen Bereich der additiven Fertigung viele Hersteller ihren AM-Anwendungen eigene Namen geben, so dass eine allgemeingültige umfassende Klassifizierung nur ansatzweise erreichbar ist.
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.
Production systems are becoming increasingly complex, which means that the main task of industrial maintenance, ensuring the technical availability of a production system, is also becoming increasingly difficult. The previous focus of maintenance efforts on individual machines must give way to a holistic view encompassing the whole production system. Against this background, the technical availability of a production system must be redefined. The aim of this publication is to present different definition approaches of production systems’ availability and to demonstrate the effects of random machine failures on the key figures considering the complexity of the production system using a discrete event simulation.
Eine Organisation hin zur Klimaneutralität zu transformieren, ist nicht nur Neuland für praktisch jeden, der loslegt: Es geht los mit dem „Wollen“, also dem Ziel, dann wird der Weg skizziert, und schließlich muss es auch noch jemand umsetzen. Aus ihren Projekten der Begleitung von Organisationen auf dem Weg zur Klimaneutralität erscheint den Autoren folgende Erfahrung des Geschäftsführers Philipp Tiefenbach der Dorfbäckerei Tiefenbach, St. Johann-Würtingen, besonders treffend: „Machen ist wie Wollen, nur krasser.“ Für eine Kommune gerät dieser Prozess zu einem „wicked problem“. Sechs Lösungswege für Kommunen erscheinen attraktiv.
Modifying the natural characteristics of PLA 3D-printed models is of interest in various research areas in which 3D-printing is applied. Thus, in this study, we describe the simple impregnation of FDM 3D-printed PLA samples with well-defined silver nanoparticles and an iron metal salt. Quasi-spherical and dodecahedra silver particles were strongly attached at the channels of 3D-printed milli-fluidic reactors to demonstrate their attachment and interaction with the flow, as an example. Furthermore, Fenton-like reactions were successfully developed by an iron catalyst impregnated in 3D-printed stirrer caps to induce the degradation of a dye and showed excellent reproducibility.
When wearing compressive garments, the tissue of the human body is altered in relation to its natural shape by the properties of the applied material and by the pattern construction used.
To check the fit of garments, both construction and selected materials can be virtually simulated in 3D on avatars in corresponding CAD programs before fabrication.
The software Blender allows the modelling of an avatar and to generate in respective to the different tissue zones with their specific properties to adjust them with soft body physics according to the testing of real soft tissue but the models in Blender are mainly using linear springs.
For a holistic assessment of the interaction between the human body and tight fitted clothing, it is necessary to consider the mechanical properties of the body. Default avatars in CAD software are usually solid and do not take this interaction into account. For this purpose, a solid avatar is converted to a deformable one by using the soft body physics implementation in the simulation program Blender. The fit of a 3D garment on both avatars are compared, which allows a first evaluation of the differences between these approaches.
Since project managers still face problems in managing interorganizational R&D projects, it is a promising approach to manage these projects project-culturally-aware. However, an important prerequisite for a project-culture-aware management is that the involved individual organizations pursue a collaborative strategy. Therefore, our article provides a conceptual approach including a new tool, the Collaborative Iron Triangle, which supports both project sponsors and managers in different phases of the collaboration process to pursue a collaborative strategy in interorganizational R&D projects.
Die additive Fertigung hat sich in den vergangenen Jahren wesentlich weiterentwickelt. Dabei wurde die Prozesstechnologie, Anlagen und die Werkstoffe optimiert. Für die industrielle Anwendung auch bei größeren Stückzahlen in der flexiblen Fertigung fehlen noch automatisierte Lösungen für die gesamte Prozesskette. In diesem Beitrag werden Werkzeuge und Technologie für die Reinigung interner Strukturelemente dargestellt.
Sägen ist ein häufig unterschätzter spanender Prozess. Oft kommt das Sägen nur zum Zuschnitt von Rohteilen zum Einsatz. Bei der Bearbeitung von Leichtbauwerkstoffen werden damit jedoch Schichten in Toleranz direkt auf die montagefertigen Konturen zugeschnitten. Zur Steigerung von Qualität und Zuverlässigkeit des Fertigungsprozesses werden maschineninterne und sensorische Daten überwacht, ausgewertet und in den Prozess zurückgekoppelt. Daher kommt es auf die gezielte Kontrolle der entscheidenden Parameter mit möglichst wenigen und robusten Schnittstellen an. Im Rahmen eines ZIM-Kooperationsprojektes (Hochschule Reutlingen, Hema Frickenhausen, Pragmatic Minds Kirchheim) wurde dies für einen Bandsägeprozess erforscht und umgesetzt.
Lehrbuch zur CAD-Software Creo Parametric und zur Produktdatenverwaltung mit Windchill.
3D-Volumenmodellierung, 3D-Flächenmodellierung, Blechmodellierung, Baugruppen- und Zeichnungserstellung, Definition von Normteilen, Erstellen von Animationen und dynamischen Analysen.
Verfahren zum Umgang mit großen Baugruppen und zur flexiblen Modellierung, Konstruk-tionsvarianten "Top-Down" und "Bottom-Up", Organisation von Konstruktionsprojekten über Skeletttechnik.
Neu: Konstruktion von und mit Mehrkörperobjekten, Rahmenkonstruktion in der Profilumgebung (AFX), intelligente Verbindungen (IFX), Live Simulation und Generatives Design.
Silicon photonic micro-ring resonators (MRR) developed on the silicon-on-insulator (SOI) platform, owing to their high sensitivity and small footprint, show great potential for many chemical and biological sensing applications such as label-free detection in environmental monitoring, biomedical engineering, and food analysis. In this tutorial, we provide the theoretical background and give design guidelines for SOI-based MRR as well as examples of surface functionalization procedures for label-free detection of molecules. After introducing the advantages and perspectives of MRR, fundamentals of MRR are described in detail, followed by an introduction to the fabrication methods, which are based on a complementary metal-oxide semiconductor (CMOS) technology. Optimization of MRR for chemical and biological sensing is provided, with special emphasis on the optimization of waveguide geometry. At this point, the difference between chemical bulk sensing and label-free surface sensing is explained, and definitions like waveguide sensitivity, ring sensitivity, overall sensitivity as well as the limit of detection (LoD) of MRR are introduced. Further, we show and explain chemical bulk sensing of sodium chloride (NaCl) in water and provide a recipe for label-free surface sensing.
This paper presents a modular and scalable power electronics concept for motor control with continuous output voltage. In contrast to multilevel concepts, modules with continuous output voltage are connected in series. The continuous output voltage of each module is obtained by using gallium nitride (GaN) high electron motility transistor (HEMT)s as switches inside the modules with a switching frequency in the range between 500 kHz and 1 MHz. Due to this high switching frequency a LC filter is integrated into the module resulting in a continuous output voltage. A main topic of the paper is the active damping of this LC output filter for each module and the analysis of the series connection of the damping behaviour. The results are illustrated with simulations and measurements.
The blockchain technology represents a decentralized database that stores information securely in immutable data blocks. Regarding supply chain management, these characteristics offer potentials in increasing supply chain transparency, visibility, automation, and efficiency. In this context, first token-based mapping approaches exist to transfer certain manufacturing processes to the blockchain, such as the creation or assembly of parts as well as their transfer of ownership. However, the decentralized and immutable structure of blockchain technology also creates challenges when applying these token-based approaches to dynamic manufacturing processes. As a first step, this paper investigates existing mapping approaches and exemplifies weaknesses regarding their suitability for products with changeable configurations. Secondly, a concept is proposed to overcome these weaknesses by introducing logically coupled tokens embedded into a flexible smart contract structure. Finally, a concept for a token-based architecture is introduced to map manufacturing processes of products with changeable configurations.
Metalworking fluids (MWFs) are widely used to cool and lubricate metal workpieces during processing to reduce heat and friction. Extending a MWF’s service life is of importance from both economical and ecological points of view. Knowledge about the effects of processing conditions on the aging behavior and reliable analytical procedures are required to properly characterize the aging phenomena. While so far no quantitative estimations of ageing effects on MWFs have been described in the literature other than univariate ones based on single parameter measurements, in the present study we present a simple spectroscopy-based set-up for the simultaneous monitoring of three quality parameters of MWF and a mathematical model relating them to the most influential process factors relevant during use. For this purpose, the effects of MWF concentration, pH and nitrite concentration on the droplet size during aging were investigated by means of a response surface modelling approach. Systematically varied model MWF fluids were characterized using simultaneous measurements of absorption coefficients µa and effective scattering coefficients µ’s. Droplet size was determined via dynamic light scattering (DLS) measurements. Droplet size showed non-linear dependence on MWF concentration and pH, but the nitrite concentration had no significant effect. pH and MWF concentration showed a strong synergistic effect, which indicates that MWF aging is a rather complex process. The observed effects were similar for the DLS and the µ’s values, which shows the comparability of the methodologies. The correlations of the methods were R2c = 0.928 and R2P = 0.927, as calculated by a partial least squares regression (PLS-R) model. Furthermore, using µa, it was possible to generate a predictive PLS-R model for MWF concentration (R2c = 0.890, R2P = 0.924). Simultaneous determination of the pH based on the µ’s is possible with good accuracy (R²c = 0.803, R²P = 0.732). With prior knowledge of the MWF concentration using the µa-PLS-R model, the predictive capability of the µ’s-PLS-R model for pH was refined (10 wt%: R²c = 0.998, R²p = 0.997). This highlights the relevance of the combined measurement of µa and µ’s. Recognizing the synergistic nature of the effects of MWF concentration and pH on the droplet size is an important prerequisite for extending the service life of an MWF in the metalworking industry. The presented method can be applied as an in-process analytical tool that allows one to compensate for ageing effects during use of the MWF by taking appropriate corrective measures, such as pH correction or adjustment of concentration.
Global, competitive markets which are characterised by mass customisation and rapidly changing customer requirements force major changes in production styles and the configuration of manufacturing systems. As a result, factories may need to be regularly adapted and optimised to meet short-term requirements. One way to optimise the production process is the adaptation of the plant layout to the current or expected order situation. To determine whether a layout change is reasonable, a model of the current layout is needed. It is used to perform simulations and in the case of a layout change it serves as a basis for the reconfiguration process. To aid the selection of possible measurement systems, a requirements analysis was done to identify the important parameters for the creation of a digital shadow of a plant layout. Based on these parameters, a method is proposed for defining limit values and specifying exclusion criteria. The paper thus contributes to the development and application of systems that enable an automatic synchronisation of the real layout with the digital layout.
Classification model of supply chain events regarding their transferability to blockchain technology
(2021)
The blockchain technology represents a decentralized database that stores information securely in immutable data blocks. Regarding supply chain management, these characteristics offer potentials in increasing supply chain transparency, visibility, automation, and efficiency. In this context, first token-based mapping approaches exist to transfer certain supply chain events to the blockchain, such as the creation or assembly of parts as well as their transfer of ownership. However, the decentralized and immutable structure of blockchain technology also creates challenges. In particular, the scalability, storage capacity, and the special requirements for storage formats make it currently impossible to map all supply chain events unrestrictedly on the blockchain. As a first step, this paper identifies important supply chain events for different use cases combining blockchain technology and supply chain management. Secondly, the supply chain events are classified in terms of their expected technical properties and their relevance for the respective use case. Finally, the identified supply chain events are evaluated regarding their transferability to blockchain technology and a classification model is introduced.
The seamless fusion of the virtual world of information with the real physical world of things is considered the key for mastering the increasing complexity of production networks in the context of Industry 4.0. This fusion, widely referred to as the Internet of Things (IoT), is primarily enabled through the use of automatic identification (Auto-ID) technologies as an interface between the two worlds. Existing Auto-ID technologies almost exclusively rely on artificial features or identifiers that are attached to an object for the sole purpose of identification. In fact, using artificial features for the purpose of identification causes additional efforts and is not even always applicable. This paper, therefore, follows an approach of using multiple natural object features defined by the technical product information from computer-aided design (CAD) models for direct identification. By extending optical instance-level 3D-Object recognition by means of additional non-optical sensors, a multi-sensor automatic identification system (AIS) is realised, capable of identifying unpackaged piece goods without the need for artificial identifiers. While the implementation of a prototype confirms the feasibility of the approach, first experiments show improved accuracy and distinctiveness in identification compared to optical instance-level 3D-Object recognition. This paper aims to introduce the concept of multisensor identification and to present the prototype multi-sensor AIS.
Ambitious goals set by the European Union strategy towards the emission reduction of multimodal logistic chains and new requirements for intermodal terminals set by the evolution of customer needs, contribute to a shift in the driver for the infrastructure development: from economy of scale to economy of density. This paper aims to present an innovative method for designing a process oriented technology chain for intermodal terminals in order to fulfill these new demanding requirements. The results of the case study of the Zero Emission Logistic Terminal Reutlingen are presented, highlighting how this particular context enables the design and development of a modular concept, paving the way for the generalization of the findings towards the transfer to similar contexts of other European cities.
Hyperspectral imaging and reflectance spectroscopy in the range from 200–380 nm were used to rapidly detect and characterize copper oxidation states and their layer thicknesses on direct bonded copper in a non-destructive way. Single-point UV reflectance spectroscopy, as a well-established method, was utilized to compare the quality of the hyperspectral imaging results. For the laterally resolved measurements of the copper surfaces an UV hyperspectral imaging setup based on a pushbroom imager was used. Six different types of direct bonded copper were studied. Each type had a different oxide layer thickness and was analyzed by depth profiling using X-ray photoelectron spectroscopy. In total, 28 samples were measured to develop multivariate models to characterize and predict the oxide layer thicknesses. The principal component analysis models (PCA) enabled a general differentiation between the sample types on the first two PCs with 100.0% and 96% explained variance for UV spectroscopy and hyperspectral imaging, respectively. Partial least squares regression (PLS-R) models showed reliable performance with R2c = 0.94 and 0.94 and RMSEC = 1.64 nm and 1.76 nm, respectively. The developed in-line prototype system combined with multivariate data modeling shows high potential for further development of this technique towards real large-scale processes.
A laboratory prototype for hyperspectral imaging in ultra-violet (UV) region from 225 to 400 nm was developed and used to rapidly characterize active pharmaceutical ingredients (API) in tablets. The APIs are ibuprofen (IBU), acetylsalicylic acid (ASA) and paracetamol (PAR). Two sample sets were used for a comparison purpose. Sample set one comprises tablets of 100% API and sample set two consists of commercially available painkiller tablets. Reference measurements were performed on the pure APIs in liquid solutions (transmission) and in solid phase (reflection) using a commercial UV spectrometer. The spectroscopic part of the prototype is based on a pushbroom imager that contains a spectrograph and charge-coupled device (CCD) camera. The tablets were scanned on a conveyor belt that is positioned inside a tunnel made of polytetrafluoroethylene (PTFE) in order to increase the homogeneity of illumination at the sample position. Principal component analysis (PCA) was used to differentiate the hyperspectral data of the drug samples. The first two PCs are sufficient to completely separate all samples. The rugged design of the prototype opens new possibilities for further development of this technique towards real large-scale application.
To correctly assess the cleanliness of technical surfaces in a production process, corresponding online monitoring systems must provide sufficient data. A promising method for fast, large-area, and non-contact monitoring is hyperspectral imaging (HSI), which was used in this paper for the detection and quantification of organic surface contaminations. Depending on the cleaning parameter constellation, different levels of organic residues remained on the surface. Afterwards, the cleanliness was determined by the carbon content in the atom percent on the sample surfaces, characterized by XPS and AES. The HSI data and the XPS measurements were correlated, using machine learning methods, to generate a predictive model for the carbon content of the surface. The regression algorithms elastic net, random forest regression, and support vector machine regression were used. Overall, the developed method was able to quantify organic contaminations on technical surfaces. The best regression model found was a random forest model, which achieved an R2 of 0.7 and an RMSE of 7.65 At.-% C. Due to the easy-to-use measurement and the fast evaluation by machine learning, the method seems suitable for an online monitoring system. However, the results also show that further experiments are necessary to improve the quality of the prediction models.
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 presents a machine learning powered, procedural sizing methodology based on pre-computed look-up tables containing operating point characteristics of primitive devices. Several Neural Networks are trained for 90nm and 45nm technologies, mapping different electrical parameters to the corresponding dimensions of a primitive device. This transforms the geometric sizing problem into the domain of circuit design experts, where the desired electrical characteristics are now inputs to the model. Analog building blocks or entire circuits are expressed as a sequence of model evaluations, capturing the sizing strategy and intention of the designer in a procedure, which is reusable across different technology nodes. The methodology is employed for the sizing of two operational amplifiers, and evaluated for two technology nodes, showing the versatility and efficiency of this approach.
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.
The planning and control of intralogistics systems in line with versatile production systems of smart factories requires new approaches and methods to cope with changing requirements within future factories. The planning of intralogistics can no longer follow a static, sequential approach as in the past since the planning assumptions are going to change in a high frequency. Reasons for these constant changes are amongst others external turbulences like rapidly changing market conditions, decreasing batch sizes down to customer-specific products with a batch size of one and on the other hand internal turbulences (like production and logistic resource breakdowns) affecting the production system. This paper gives an insight into research approaches and results how capabilities of intelligent logistical objects (intelligent bins, autonomous transport systems etc.) can be used to achieve a self-organized, cost and performance optimized intralogistics system with autonomously controlled process execution within versatile production environments. A first consistent method has been developed which has been validated and implemented within a scenario at the pilot factory Werk150 at the ESB Business School (Reutlingen University). Based on the incoming production orders, the method of the Extended Profitability Appraisal (EPA) covering the work system value to define the most effective work system for order fulfilment is applied. To derive the appropriate intralogistics processes, an autonomous control method involving principles of decentralized and target-oriented decision-making (e.g. intelligent bins are interacting with autonomously controlled transport systems to fulfil material orders of assembly workstations) has been developed and applied to achieve a target-optimized process execution. The results of the first stage research using predefined material sources and sinks described in this paper is going to set the basis for the further development of a self-organized and autonomously controlled method for intralogistics systems considering dynamic source and sink relations. By allowing dynamic shifts of production orders in the sense of dynamic source and sink relations the cost and performance aims of the intralogistics system can be directly aligned with the aims of the entire versatile production system in the sense of self-organized and autonomously controlled systems.
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.
Der hohe Stellenwert von Energiedienstleistungen steht für Energieversorger außer Zweifel. Der Handlungsbedarf bleibt aber nach wie vor immens, erforderliche Change-Prozesse werden erst in wenigen Fällen aktiv und gezielt gestaltet. Dies sind die zentralen Ergebnisse einer gemeinsamen empirischen Studie vom "Reutlinger Energiezentrum für Dezentrale Energiesysteme und Energieeffizienz (REZ) an der Hochschule Reutlingen und der international tätigen Unternehmensberatung kwp consulting group.
Im Projekt GalvanoFlex_BW sind verschiedene Möglichkeiten zur Verbesserung der Energieeffizienz von energieintensiven Industrieunternehmen aufgezeigt und untersucht worden. Die Einführung der KWK im stromoptimierten Betrieb stellte dabei einen besonders betrachteten Aspekt dar. Neben der technischen Untersuchung ist zudem eine sozialwissenschaftliche Betrachtung vorgenommen worden, um die Einführung und Umsetzung entsprechender Maßnahmen auch unter diesem Aspekt zu betrachten. Ein zusätzlicher wichtiger Schwerpunkt des Projektes war die Übertragung des erarbeiteten Wissens an weitere Unternehmen, Institutionen etc., die nicht direkt am Projekt beteiligt waren.
Durch die Zusammenarbeit von vier Forschungs- und drei Industriepartnern sind die Arbeiten praxisorientiert auf Basis realer Messdaten sowie im Zuge von Befragungen der handelnden Personen bei den Projektpartnern im Sinne eines Reallabors durchgeführt worden.
Die Notwendigkeit zur Einsparung von Energie und damit zur Umsetzung von Effizienzmaßnahmen ist ein wichtiger Schritt, um die von der EU geplante Reduktion von Treibhausgasen zu erreichen. Darüber hinaus ist zu erwarten, dass die Energiekosten auch zukünftig weiter ansteigen. Dadurch werden Maßnahmen zur Steigerung der Energieeffizienz zu einem wichtigen Element, eine wettbewerbsfähige Produktion zu gewährleisten. Im Rahmen des Projektes sind deshalb verschiedene Energieeffizienzmaßnahmen speziell für die Galvanotechnik recherchiert, analysiert und in einen Maßnahmenkatalog überführt worden. Des Weiteren wurde eine Bewertungsmethode entwickelt, die die Unternehmen der Galvanotechnik bei der Identifikation von sinnvollen Energieeffizienzmaßnahmen unterstützen soll.
Bei den Untersuchungen zur Umsetzung von Kraft-Wärme-Kopplungsanlagen konnte am Beispiel von zwei Unternehmen mit stark unterschiedlichen Strom- und Wärmebedarfswerten gezeigt werden, dass der Einsatz entsprechender Anlagen wirtschaftlich lohnenswert ist. Im günstigsten Fall ergeben sich Amortisationszeiten von etwa zwei Jahren. Es hat sich weiterhin gezeigt, dass die Auslegung des Block-heizkraftwerkes stark von den Strom- und Wärmebedarfswerten abhängt und dass der Pufferspeicher keinesfalls zu klein ausgelegt werden sollte. Eine intelligente stromoptimierte Steuerung mit Lastspitzenmanagement kann die Wirtschaftlichkeit jedoch häufig nur noch wenig gegenüber dem wärmegeführten Betrieb verbessern. Ursache dafür ist, dass das derzeitige Förder- und Vergütungssystem für Kraft-Wärme-Kopplungsanlagen nahezu keine Anreize für einen am Strombedarf und damit an der Deckung von Residuallast orientierten Betrieb bietet. Einzig bei Unternehmen mit ausgeprägten Spitzen im Strombezug, kann der gezielte Einsatz eines Blockheizkraftwerkes zu einer signifikanten Senkung des Leistungspreises führen.
Darüber hinaus ist die Einführung einer Kraft-Wärme-Kopplungsanlage generell als komplexe Energieeffizienzmaßnahme anzusehen, die deshalb neben den wirtschaftlichen Aspekten erhöhte Anforderungen an die Unternehmen und das professionelle Umfeld stellt, die im Rahmen der sozialwissenschaftlichen Begleitforschung untersucht worden sind. Dabei konnten Treiber aber auch Hemmnisse zur Umsetzung der Technologie sowohl innerhalb der Unternehmen als auch außerhalb identifiziert werden. Die internen Hemmnisse sind dabei auf unterschiedliche Ursachen zurückzuführen, wie die hohe Komplexität der KWK-Technologie, die schwierige Bewertung des Gesamtnutzens im Unternehmen, die mangelnde personelle Ausstattung und fehlende Unternehmerentscheidungen. Abhilfe schaffen, und damit als Treiber wirken, können hier ein verbessertes Beratungsangebot insbesondere seitens neutraler Stellen sowie der Anlagenbetrieb im Contracting.
Die Übertragung der im Projekt erarbeiteten Ergebnisse ist bereits während der Projektlaufzeit über die Branchenplattform im Zuge verschiedener Workshops, die speziell auf Unternehmen und Institutionen außerhalb des Projektkonsortiums ausgerichtet waren, erfolgt. Zur Verstärkung der Verbreitung des erarbeiteten Wissens ist zum Projektende eine Serie aus vier Fachartikeln in einem namhaften Branchenmagazin erschienen, und es ist eine Internetseite zum Projekt erstellt worden (www.galvanoflex_bw.de). Letztere hat dabei nicht nur die Aufgabe der Wissensverbreitung, sondern sie soll auch über das Projektende hinaus als Kontaktplattform dienen, um die Umsetzung von Effizienzmaßnahmen mit dem im Projekt generierten Wissen zu unterstützen.
Enhancing data-driven algorithms for human pose estimation and action recognition through simulation
(2020)
Recognizing human actions, reliably inferring their meaning and being able to potentially exchange mutual social information are core challenges for autonomous systems when they directly share the same space with humans. Intelligent transport systems in particular face this challenge, as interactions with people are often required. The development and testing of technical perception solutions is done mostly on standard vision benchmark datasets for which manual labelling of sensory ground truth has been a tedious but necessary task. Furthermore, rarely occurring human activities are underrepresented in these datasets, leading to algorithms not recognizing such activities. For this purpose, we introduce a modular simulation framework, which offers to train and validate algorithms on various human-centred scenarios. We describe the usage of simulation data to train a state-of-the-art human pose estimation algorithm to recognize unusual human activities in urban areas. Since the recognition of human actions can be an important component of intelligent transport systems, we investigated how simulations can be applied for his purpose. Laboratory experiments show that we can train a recurrent neural network with only simulated data based on motion capture data and 3D avatars, which achieves an almost perfect performance in the classification of those human actions on real data.
We discuss the fabrication technologies for IC chips in this chapter. We will focus on the main process steps and especially on those aspects that are of particular importance for understanding how they affect, and in some cases drive, the layout of ICs. All our analyses in this chapter will be for silicon as the base material; the principles and understanding gained can be applied to other substrates as well. Following a brief introduction to the fundamentals of IC fabrication (Sect. 2.1) and the base material used in it, namely silicon (Sect. 2.2), we discuss the photolithography process deployed for all structuring work in Sect. 2.3. We will then present in Sect. 2.4 some theoretical opening remarks on typical phenomena encountered in IC fabrication. Knowledge of these phenomena is very useful for understanding the process steps we cover in Sects. 2.5–2.8. We examine a simple exemplar process in Sect. 2.9 and observe how a field-effect transistor (FET) – the most important device in modern integrated circuits—is created. To drive the key points home, we provide a review of each topic at the end of every section from the point of view of layout design by discussing relevant physical design aspects.
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.
Planning of available resources considering ergonomics under deterministic highly variable demand
(2020)
In this paper, a method for hybrid short- to long-term planning of available resources for operations is presented, which is based on a known or deterministically forecasted but highly variable demand. The method considers quantitative measures such as the performance and the availability of resources, ergonomically relevant KPI and ultimately process costs in order to serve as a pragmatic planning tool for operations managers in SMEs. Specifically, the method enables exploiting the ergonomic advantages of available flexible automation technology (e.g. AGVs or picking robots), while assuring that these do not represent a capacity bottleneck. After presenting the method along with the necessary assumptions, mainly concerning the availability of data for the calculations, we report a case study that quantifies the impact of throughput variability on the selection of different process alternatives, where different teams of resources are used.