Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Characterization and application of assistance systems in digital engineering
    ( 2021)
    Stark, Rainer
    ;
    Brandenburg, Elisabeth
    ;
    Lindow, Kai
    A broad range of assistance systems can be found in manufacturing practice as well as in the corresponding literature. Similarly, it can be observed that there is a growing need for and an increasing supply of assistance systems of all kinds. However, for digital manufacturing, the assistance systems are not clearly characterized. The diversity in application areas and possible uses varies and there are no possibilities for comparison. This paper addresses the topic of assistance systems and examines the various basic elements of engineering activities in terms of possible types of assistance systems based on research in manufacturing industry. Crucial aspects of assistance capabilities for engineering are elaborated and possible digital approaches are validated based on investigations in the field of aircraft engine design and assembly.
  • Publication
    Applying Contextualization for Data-Driven Transformation in Manufacturing
    ( 2020)
    Gogineni, Sonika
    ;
    Lindow, Kai
    ;
    Nickel, Jonas
    ;
    Stark, Rainer
    Manufacturing is highly distributed and involves a multitude of heterogeneous information sources. In addition, Production systems are increasingly interconnected, hence leading to an increase in heterogeneous data sources. At present, data available from these new type of systems are growing faster than the ability to productively integrate them into engineering and production value chains of companies. Known applications such as predictive maintenance and manufacturing equipment management are currently being continuously optimized. While these applications are designed to help companies manage their manufacturing and engineering data, they only use a fraction of the total potential that can be realized by linking manufacturing and engineering data with other enterprise data. In the future, the context in which the data can be set will play an essential role. A meaningful added value in manufacturing can be achieved only with context specific data. Against this background, this paper presents three main areas of application for contextualizing data (semantics, sensitivity and visualization) and explains these applications with the help of a contextualization architecture. The concept is also evaluated using an industrial example. Furthermore, the paper describes the theoretical background of contextualization and its application in industry. The major challenges of the ability of engineers to adapt their activities and the integration of process knowledge for semantic linking are addressed as well.
  • Publication
    Data preparation for data analytics (DPDA)
    ( 2019)
    Stark, Rainer
    ;
    Deuse, Jochen
    ;
    Damerau, Thomas
    ;
    Reckelkamm, Thorsten
    ;
    Lindow, Kai
  • Publication
    Development and operation of Digital Twins for technical systems and services
    ( 2019)
    Stark, Rainer
    ;
    Fresemann, Carina
    ;
    Lindow, Kai
    Digital Twins are new solution elements to enable ongoing digital monitoring and active functional improvement of interconnected products, devices and machines. In addition, benefits of horizontal and vertical integration in manufacturing are targeted by the introduction of Digital Twins. Using the test environment of smart factory cells, this paper investigates methodological, technological, operative, and business aspects of developing and operating Digital Twins. The following Digital Twin dimensions are considered in scientific and application oriented analysis: (1) integration breadth, (2) connectivity modes, (3) update frequency, (4) CPS intelligence, (5) simulation capabilities, (6) digital model richness, (7) human interaction, and (8) product lifecycle. From this, design elements for the development of Digital Twins are derived and presented.
  • Publication
    Implementation of an Energy Metering System for Smart Production
    ( 2019)
    Halstenberg, Friedrich A.
    ;
    Lindow, Kai
    ;
    Stark, Rainer
    Digitization is consecutively changing more and more areas of human living. Many products are designed increasingly ""smart"" and connected to their environment. Not only products but also the necessary production facilities and systems are subject to digital change. The goal is to achieve a wide range of improvements and increase the efficiency and flexibility of the interlinked production systems. In Industry 4.0, important production parameters are measured and monitored with the help of sensors. Based on analyses of those data, adjustments and improvements of the production system can be performed. This paper presents the concept and physical implementation of an advanced energy metering system on a factory demonstrator, the so-called SmartFactory 4.0. It produces beverage coasters, which can be designed freely by the customer in shape, material and colour and is produced directly or remotely through a web application. The SmartFactory 4.0 consists of three production modules, which are connected to one another by means of media and information technology. The advanced energy metering system is designed in order to measure and monitor energy consumptions in various production steps. Those data are compared to previous simulations. Steps for the improvement of the energy efficiency of the SmartFactory 4.0 are derived. This paper presents first test results from the application of the system. For different individualized gravures and two different colours (green and orange) with various depths of the produced beverage coaster, energy consumptions of the production have been metered over time. The measured data are analysed and evaluated, and suitable steps for improvement are given. Finally, this research provides suggestions for scaling the energy metering system to larger production systems, and a systematic procedure for implementation is given. This research constitutes one step in the direction of utilizing the concept of the digital factory twin for the improvement of energy efficiency and sustainability of production systems.
  • Publication
    Feedback to Design with Digital Lifecycle-Twins - literature review and concept presentation
    ( 2018)
    Riedelsheimer, Theresa
    ;
    Lindow, Kai
    ;
    Stark, Rainer
    In this paper, the authors propose a concept for optimizing the design process as well as product-related features and services through learning from Digital Twin data and establishing a continuous feedback loop from downstream phases of the product lifecycle to the design phase. As a first step, a systematic review of existing concepts in literature as well as a gap analysis is conducted. The presented concept details existing Digital Twin concepts and implementations by focusing on the specific objective of realizing Feedback to Design and integrating the lifecycle aspect.
  • Publication
    Study on sustainability developments in industrial practice
    ( 2018)
    Lindow, Kai
    ;
    Kaluza, Andrea
    ;
    Stark, Rainer
    Traditionally, manufacturing companies focus on the value-adding processes at production sites but during the last decades, life-cycle thinking is emphasized. The principle of Sustainable Development contributes as a significant driver for this way of thinking. It demands manufacturing companies to implement sustainable aspects into their engineering actions. The state of the art shows that theoretical solutions to integrate sustainability into a company exist at all corporate levels (normative, strategic and operational). Against this background, the question arises how companies are actually implementing sustainability. Within this study, the company's internal implementations were examined. Eventually, the need for action is identified and future recommendations are described.
  • Publication
    Investigating challenges of a sustainable use of marine mineral resources
    ( 2018)
    Kaluza, Andrea
    ;
    Lindow, Kai
    ;
    Stark, Rainer
    High-tech products as well as renewable energy systems require ever-increasing quantities and more different metals. The extraction of metals and industrial minerals for the production of consumer goods and machines take place almost exclusively on land now. However, the interest in marine mineral resources has been re-inflamed due to the problem of geopolitical availability, such as fragile or failed raw material states and oligopolistic structures among the producers. This article gives a brief outline of the political, social and economic context of this change in interest in marine mineral raw materials extraction.
  • Publication
    Target-driven selection and scheduling of methods for sustainable product development
    ( 2017)
    Buchert, Tom
    ;
    Halstenberg, Friedrich A.
    ;
    Bonvoisin, Jeremy
    ;
    Lindow, Kai
    ;
    Stark, Rainer
    A large number of methods have been developed in order to systematically consider sustainability as a design criterion in the product development process. However, further support is required to help product development teams to assess the applicability of the existing methods in the specific design contexts. In order to address this problem, the Design Decision Support Assistant (DDSA)-an IT-based assistance system-has been developed to support product development teams in the selection, scheduling, and application of sustainable product design methods in the product development process. The backbone of the assistant is a method repository comprising 29 methods for sustainable product development as well as a method taxonomy to enable the selection and scheduling of suitable methods for achieving sustainability-related design targets. This article introduces the concept of the DDSA, details its practical prototypical implementation, and illustrates its application in a case study.
  • Publication
    Industrie 4.0 - Digitale Neugestaltung der Produktentstehung und Produktion am Standort Berlin
    ( 2016)
    Stark, Rainer
    ;
    Damerau, Thomas
    ;
    Lindow, Kai
    Ende 2015 konnten bundesweit rund 449 Forschungs- und Umsetzungsprojekte dem Thema Industrie 4.0 zugeordnet werden. Die großen Herausforderungen bestehen nunmehr einerseits darin, entstandene Partiallösungen, neue Erkenntnisse und Resultate in die flächendeckende und standardisierte Anwendung zu überführen, während anderseits ""weiße Flecken"" identifiziert und konsequent weiter beforscht werden müssen. Das Kapitel stellt innovative Industrie 4.0 Projekte für den realen und digitalen Fabrik- und Produktbetrieb aus dem Produktionstechnischen Zentrum (PTZ) in Berlin vor und bietet eine Forschungslandkarte zur Einordnung eigener Aktivitäten an. Anhand eines Stufenmodells wird verdeutlicht wie die Implementierung und Operationalisierung des künftig notwendigen Informationsmanagements praktisch gelingen kann. Anhand des zukunftsweisenden Konzeptes der Informationsfabrik wird verdeutlicht, wie mittels des Digitalen Zwillings und Smart Data fortan Effizienz- und Effektivitätsgewinne in der Produktentstehung und Produktion realisiert werden.