Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Functional Architecture for Solution Independent Realizations of Digital Continuity in System Development

2023 , Manoury, Marvin Michael

Product and service creation requires the interdisciplinary collaboration of different stakeholders. In virtual product and service creation these stakeholders generate models and data to describe the product or service over their entire life cycle. For a reliant product creation and optimization, these models and data need to be consistent through all disciplines and life cycle phases. In this publication, a solution-independent functional architecture to foster the digital continuity across the involved disciplines and life cycle phases is described. To achieve it, existing approaches in literature are evaluated and requirements and desired capabilities extracted. An reduced form of the Architecture Analysis & Design Integrated Approach (ARCADIA) is used to describe a functional architecture. Consecutively, existing solutions are mapped to the architecture and evaluated for compliance.

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Conceptual Approach for a Digital Value Creation Chain Within the Timber Construction Industry - Potentials and Requirements

2023 , Schramm, Nico , Oertwig, Nicole , Kohl, Holger

This paper addresses the megatrend of urbanization as well as the associated challenges of climate change and its relation to sustainable manufacturing. An enormous lever for improving the climate balance is offered by the consistent use of renewable building materials. In the Berlin/Brandenburg metropolitan region, wood as a building material in particular should play a central role in achieving the climate targets. To realize this, it is not only necessary to use the potential of wood as a raw material for storing carbon, but also to embed wood construction in regional value chains and integrated digital production systems in order to be able to optimally design innovative value creation fields, new regional products and efficient material cycles for increasing sustainability. In the context of this work, the information flows along the value chain are investigated and transferred into a digital model. Existing digital concepts such as the “Open BIM” approach (Building Information Modeling) have been incorporated and shape the entirety of the value chain module developed in this paper for serial prefabrication in multi-story timber construction. Material and information flows are analyzed, interfaces between the actors are identified, value-adding factors of timber system construction are systematically examined for their effects, and industrial prefabrication is aligned with a digital model.

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Digital Twins for Sustainability in the Context of Biological Transformation

2023 , Seegrün, Anne , Mügge, Janine , Riedelsheimer, Theresa , Lindow, Kai

Applying biological principles that are similar to those found in nature to product engineering and manufacturing offers new approaches to product and production systems and might lead to a significant contribution towards sustainability. By transferring materials, structures, and processes of natural to digital ecosystems industrial value creation can be optimized. A promising approach to establish a networked, self-regulating digital ecosystem represents a digital twin. The potential of digital twins within the context of biological transformation has not been researched yet. This paper attempts to provide a first entry into the research topic by identifying biological principles within the concept of a digital twin and analyzing its potential for biological transformation in the industry. As a main result, the paper presents a list of relevant principles of biological transformation based on a structured taxonomy. These are specified within the concept of a digital twin.

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Analyse und Nutzung von Aluminium-Bronze-Schleifstaub für das Laser-Pulver-Auftragsschweißen

2022-12 , Müller, Vinzenz , Marko, Angelina , Kruse, Tobias , Biegler, Max , Rethmeier, Michael

Die additive Fertigung verspricht ein großes Potenzial für den maritimen Sektor. Insbesondere Directed Energy Deposition (DED) Verfahren bieten die Möglichkeit, großvolumige maritime Bauteile wie Propellernaben oder -schaufeln herzustellen. Bei der Nachbearbeitung solcher Bauteile fällt in der Regel eine große Menge an Schleifabfällen an. Ziel des vorgestellten Projekts ist die Entwicklung einer nachhaltigen zirkulären AM-Prozesskette für maritime Komponenten auf Basis von Aluminiumbronze-Schleifresten. Dazu soll das Material wiederaufbereitet und anschließend als Rohmaterial für die Herstellung von Schiffspropellern im Laser-Pulver DED-Verfahren verwendet werden. In der vorliegenden Arbeit werden Schleifabfälle mittels dynamischer Bildanalyse untersucht und mit kommerziellem DED-Pulver verglichen. Anschließend werden Probengeometrien aus Schleifstaub gefertigt und durch metallographische Schliffe und REM/EDX analysiert.

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Considering LCA in System Architectures of Smart-Circular PSS

2023 , Kruschke, Thomas , Riedelsheimer, Theresa , Lindow, Kai

The realization of smart-circular Product-Service Systems has theoretically promising advantages compared to traditional products. Nevertheless, the sustainability improvement, especially for the ecological dimension is not yet satisfactorily proved. In this paper, the authors examined the current state of research within a systematic literature review with a specific focus on the overlap of the topics: Life Cycle Assessment, Model-Based Systems Engineering, Product-Service Systems, and Circular Economy. The aim is to analyze the potential of a proactive quantification of the ecological impact in an early stage during the development of smart-circular PSS - the system architecture definition. As a result of the systematic review, 27 relevant papers were identified and analyzed and the findings are presented in a structured way. The main finding is that the current state of the art in this research field still is in the conceptualization stage. In addition, a proactive approach is rare and circularity is not considered to its fullest. Quantified use cases do not draw the system boundaries Cradle-to-Cradle and not every of the 9R-strategies is considered. Furthermore, the potentials and challenges of the revealed research gap are summarized.

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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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Requirements for the Development of a Performance Management System with Consideration of Unforeseeable Business Process Variants

2023 , Teng, Yu-Min , Ay, Sila , Iyer, Rishabh , Scholz, Julia-Anne

Supply chain issues arising from market turbulences force companies to find new solutions in the short term. Hence, deviations from the ideally designed business processes are inevitable, especially during production planning and control. These deviations result in unforeseen process variants. In addition, process steps of those process variants are often not completely conducted with IT systems and are therefore difficult to trace. Another underlying problem lies in the bias of performance measurement of process variants because each variant aligns with different goals and framework conditions. For these and other reasons, the performance management of process variants presents a challenge. To overcome this challenge, a serious game is being further developed in a research project. The goal is to provide trainings for performance management in a turbulent business environment with the serious game. It simulates the business processes and supply chain issues of a drilling machine manufacturer and serves as a use case for the research presented in this paper. The challenges associated with the performance management of unforeseeable business process variants are derived from the use case. A gap analysis is conducted between the challenges and existing requirements for the development of performance management systems. Based on this, adjustments are proposed to existing requirements and new requirements are being developed.

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A Practical Approach to Realize a Closed Loop Energy Demand Optimization of Milling Machine Tools in Series Production

2023 , Can, Alperen , Schulz, Hendrik , El-Rahhal, Ali , Thiele, Gregor , Krüger, Jörg

Energy efficiency is becoming increasingly important for industry. Many approaches for energy efficiency improvements lead to the purchase of new hardware, which could neglect the sustainability. Therefore, optimizing the energy demand of existing machine tools (MT) is a promising approach. Nowadays energy demand optimization of MT in series production is mainly done manually by the operators, based on implicit knowledge gained by experience. This involves manual checks to ensure that production targets like product quality or cycle time are met. With data analytics it is possible to check these production targets autonomously, which allows optimizing production systems data driven. This paper presents the approach and evaluation of a closed loop energy demand optimization of auxiliary units for milling MT during series production. The approach includes, inter alia, a concept for machine connectivity using edge devices and a concept for validating production targets

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Literature Review of Biological Transformation in Holistic Production Systems

2023 , Lange, Annika , Poeche, Moritz

In today’s manufacturing world, there are large, interconnected production networks. Production is constantly influenced by trends such as the Toyota production concept or Holistic Production System. Numerous companies have already introduced a Holistic Production System. Though, to achieve the greatest success with it, the Holistic Production System must be implemented across the entire production network. This means that more and more companies are setting a condition for their suppliers: They must also implement a Holistic Production System. However, not only the introduction but also the maintenance of a Holistic Production System is associated with a high level of effort. To reduce the effort required for a Holistic Production System, Biological Transformation offers a promising approach. Especially since principles from nature are resource-saving. This paper presents a systematic literature review. This review examines the extent to which biological principles are already being used in Holistic Production Systems.

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Untersuchung zum Elektronenstrahlschweißen von additiv gefertigtem Inconel 939

2022-12 , Raute, Maximilian Julius , Biegler, Max , Rethmeier, Michael

Hochfeste Nickelbasislegierungen wie Inconel 939 spielen eine wesentliche Rolle im modernen Turbinenbau. Additive Fertigungstechnologien eröffnen hierbei neue Möglichkeiten für die Verarbeitung, jedoch fehlen verlässliche Fügeprozesse für die Absicherung der additiven Prozesskette im Bereich Neuteilfertigung und Instandsetzung. Insbesondere Heißrisse stellen eine große Herausforderung an die Fügetechnik. Die vorliegende Untersuchung befasst sich daher mit dem Verhalten von additiv gefertigten Blechen aus Inconel 939 beim Elektronenstrahlschweißen. Es werden grundlegende Zusammenhänge zwischen Prozessparametern, Härte und Rissneigung betrachtet und Ansätze für eine Optimierung auf Basis statistischer Versuchsplanung aufgezeigt. Hierbei erfolgt eine Einteilung der Risse nach bestimmten Nahtbereichen. Risse am Nahtkopf können durch die Faktoren Vorschub und Streckenenergie sowie die Härte des Schweißgutes beeinflusst werden. Risse im Bereich der parallelen Nahtflanken stehen hingegen im Zusammenhang mit der Härte der Wärmeinflusszone. Ein abschließender Vergleich der angepassten Parameter mit der Ausgangssituation zeigt, dass durch Anwendung der statistischen Optimierung eine deutliche Reduzierung der Rissneigung erreicht werden kann.

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