Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Project-Based Learning in Engineering Education – Developing Digital Twins in a Case Study

2023 , Hagedorn, Lisa , Riedelsheimer, Theresa , Stark, Rainer

The current engineering environment demands for an increasing level of interdisciplinarity, innovation, creativity and cross-domain thinking as well as the consideration of sustainability aspects. New concepts, such as Digital Twins and complex product systems lead to the need for integrated product development approaches and new methods that put the user perspective in focus. This also needs to be an integral part in today's teaching concepts of the next generation of engineers.At the Department of Industrial Information Technology of the Technical University of Berlin, a case study was conducted by applying a concept of project-based learning in the engineering domain to address these challenges. In this paper, the case study as well as the method and its validation are presented. Students from different engineering disciplines had the task of developing virtual and physical prototypes for a sustainable, complex product system with a digital twin and respective sustainable business models. Within a structured survey, the teaching concept and the applied method were validated and lessons learned as well as further improvement measures are derived.

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Methodology for a reverse engineering process chain with focus on customized segmentation and iterative closest point algorithms

2022 , Mönchinger, Stephan , Schröder, Robert , Stark, Rainer

One-off construction is characterized by a multiplicity of manual manufacturing processes whereby it is based on consistent use of digital models. Since the actual state of construction does not match the digital models without manually updating them, the authors propose a method to automatically detect deviations and reposition the model data according to reality. The first essential method is based on the ""Segmentation of Unorganized Points and Recognition of Simple Algebraic Surfaces"" presented by Vanco et al.. The second method is the customization of the iterative closest point (ICP) algorithm. The authors present the overall structure of the implemented software, based on open source and relate it to the general reverse engineering (RE) framework by Buonamici et al.. A highlight will be given on: the general architecture of the software prototype; a customized segmentation and clustering of unorganized points and recognition of simple algebraic surfaces; the deviation analysis with a customized iterative closest point (CICP) algorithm Especially in the field of one-off construction, characterized by small and medium companies, automated assessment of 3D scan data during the design process is still in its infancy. By using an open source environment progress for consistent use of digital models could be accelerated.

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Systematic Literature Review of System Models for Technical System Development

2021 , Manoury, Marvin Michael , Zimmermann, Thomas , Stark, Rainer

In Model-Based Systems Engineering (MBSE) there is yet no converged terminology. The term 'system model' is used in different contexts in literature. In this study we elaborated the definitions and usages of the term 'system model', to find a common definition. We analyzed 104 publications in depth for their usage and definition as well as their meta-data e.g., the publication year and publication background to find some common patterns. While the term is gaining more interest in recent years, it is used in a broad range of contexts for both analytical and synthetic use cases. Based on this, three categories of system models have been defined and integrated into a more precise definition.

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Validation of Immersive Design Parameters in Driving Simulation Environments

2021 , Lyga, Yvonne , Lau, Merle , Brandenburg, Elisabeth , Stark, Rainer

Driving simulators are used for the prospective validation of technical systems in the automotive sector. The design of simulation environments can affect drivers and should be considered in investigations of driver-vehicle interactions. The aim of this research is to minimize the gap between driving simulators and real car studies by integrating immersive parameters into simulated driving environments. Stereoscopy, surround sound and motion feedback were analyzed with regard to driver behavior and experience and were then compared to data of a real drive from a previous investigation. The authors conducted a study with N = 48 participants performing a dual-task scenario in a driving simulator. Results reveal significant effects of immersive design parameters on gaze behavior and mental workload. Findings provide guidance for an efficient and cost-effective development of driving simulation environments.

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Taxonomy for Biological Transformation Principles in the Manufacturing Industry

2023 , Berkhahn, Magda , Kremer, Gerald , Riedelsheimer, Theresa , Lindow, Kai , Stark, Rainer

Industry and research are seeking answers to current demands in industrial value creation, like resilience of production, sufficient product quality and sustainability of products and processes. A novel line of thought, seeking the accomplishment of those is the Biological Transformation (BT). BT describes the interweaving of biological modes of action, materials and organisms with engineering and information sciences. The conflation of disciplines from natural, technical and social sciences yields in a heterogeneous field of activities with ambiguous technical terms. An ascertainment of principles of BT is required to classify yet undifferentiated patterns in nature-based production, facilitating their systematic implementation in aiming for sustained solutions on current challenges. With increasing research in biomimetic, attempts arise to capture nature‑based activities in manufacturing through schematic classifications. Yet, basic semantics representing the effective principles of BT in the manufacturing industry is lacking. The goal of this publication is to introduce a taxonomy of Biological Transformation in manufacturing based on its core principles Bio Inspiration, Bio Integration and Bio Interaction. Within the research project BioFusion 4.0, the taxonomy was developed and applied to classify technology innovations. The paper presents the taxonomy, its development and application in use cases.

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Production in the loop - the interoperability of digital twins of the product and the production system

2021 , Vogt, Anna , Schmidt, Philipp Heiner , Mayer, Sebastian , Stark, Rainer

The Internet of Things (IoT) era facilitates new possibilities at the interface between the lifecycle of the product and the manufacturing disciplines allowing to add value and meet growing legal requirements. This work presents use cases from the automobile industry which are analyzed in order to derive requirements for data exchange. The analysis of the use cases shows clearly that we need to focus on the instance level for this purpose. This means that both, a specific unit of the product and the production system, must be considered. As a solution approach, a communication loop is proposed bringing the Digital Twin concept in a new field of usage. The key aspect of the proposed solution is the direct intercommunication between the Digital Twins of the product being produced as a Cyber-Physical System (CPS) and the production resources as Cyber-Physical Production Systems (CPPS). This solution enables the aggregation of production-related data within the products Digital Twin and therefore promotes maximal transparency throughout engineering disciplines, phases of the product lifecycle and the whole supply chain.

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Interaction between capabilities of Model Based Systems Engineering on sensor models

2021 , Manoury, Marvin Michael , Schmidt, Simon , Stark, Rainer

In modern product development, models are often used for different purposes, e.g., system synthesis, trade-off analysis of system parameters or visualization and creation of design concepts. For some models, this purpose as well as the model itself might change over time. New interactions with the target system can occur and new details are added over time. Both have to be integrated immediately into the development procedure. When models are not maintained up to date and not used by different stakeholders, the benefits of the model-based approach are lessened due to the effort for generation and maintenance. The five development capabilities of MBSE, comprising Systems Environment Analytics (SEA), Systems Definition and Derivation (SDD), Systems Interaction Modeling (SIM), Systems Lifecycle Engineering (SLE) and the MBSE Capability and Maturation Matrix (CMM) address this topic on a capability level.In this article, the authors point out the interaction between these d evelopment capabilities on the example of a Pedestrian Emergency Braking System (PEBS) development in automotive industry, with a focus on sensor models. It will be shown exemplary how one development capability might influence another and how this interaction supports the development of complex systems.

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Literature review of quality attributes for collaborative product development

2022 , Randermann, Marcel , Blüher, Till , Jochem, Roland , Stark, Rainer

In collaborative product development, diverse stakeholders are involved in distributed engineering activities. This situation makes it difficult to ensure, manage, and improve the quality across company boundaries. Therefore, this work determines the characteristics of collaborative engineering which have an influence on the quality of distributed product development. Several interoperability frameworks were analyzed in order to get insights into key areas for collaboration design. Furthermore, a systematic literature review provided the best practices for improvement efforts. The derived quality attributes were condensed and adapted to collaborative product development in the four key areas of organization and processes, data/artifacts, information technology systems and infrastructure, and social factors. This enables product developers to examine their collaborative engineering environment and to identify room for improvement and to enhance quality. A case example of an engineering change order shows a collaborative data flow process, in which the quality attributes may indicate improvement measures.

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Enabling automated engineering's project progress measurement by using data flow models and digital twins

2021 , Ebel, Helena , Riedelsheimer, Theresa , Stark, Rainer

A significant challenge of managing successful engineering projects is to know their status at any time. This paper describes a concept of automated project progress measurement based on data flow models, digital twins, and machine learning (ML) algorithms. The approach integrates information from previous projects by considering historical data using ML algorithms and current unfinished artifacts to determine the degree of completion. The information required to measure the progress of engineering activities is extracted from engineering artifacts and subsequently analyzed and interpreted according to the project's progress. Data flow models of the engineering process help understand the context of the analyzed artifacts. The use of digital twins makes it possible to connect plan data with actual data during the completion of the engineering project.

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Methodology to develop Digital Twins for energy efficient customizable IoT-Products

2021 , Riedelsheimer, Theresa , Gogineni, Sonika , Stark, Rainer

Products are increasingly individualized and enhanced to be able to communicate, e.g. via Industrial Internet of Things (IoT). However, the impact of products on sustainability (environmental and social) across their life is often not considered and analyzed. IoT-based or smart products, that are able to communicate, generate data, which can be used to monitor and optimize sustainability indicators. The Digital Twin (DT) is a new technological concept which focuses on product individual data collection and analysis. It provides the possibility to make use of the available data and optimize the systems individual sustainability as well as future product generations. However, the design and realization of such a DT requires new approaches and capabilities, which is an identified research gap. Therefore, this paper presents a methodology to develop DTs of physical IoT-based products, the so called DT V-Model with the aim to optimize the systems sustainability, specifically environmental aspects. It is based on the V-model for the development of smart products and is enhanced with additional roles and approaches for DT development. The methodology is described in detail. The result of a development cycle according to the DT-V-Model is a tested concept of a DT, which includes Digital Master (DM) data from the planning phase and Digital Shadow (DS) data from the production, operation and End of Life-phase. For a DT for energy efficiency, the Digital Master model consists of the information and models from the product development phase including the planned production and use phase energy consumption. The Digital Shadow consists of the actual production energy consumption and the use phase energy consumption. The methodology is applied to a use case of an IoT-based consumer product that can be customized to a certain degree by the consumer. A DT is developed to monitor and optimize the products energy efficiency in production and use. The necessary elements of the DT and the capabilities are depicted. The paper shows the feasibility of the methodology for the development of DTs, the necessary adaptions to common approaches for development and the specific characteristics of DT development for the aim of energy efficiency.

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