Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Virtual Prototyping and Validation of Cpps within a New Software Framework
    ( 2017)
    Neumeyer, S.
    ;
    Exner, K.
    ;
    Kind, S.
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    Hayka, H.
    ;
    Stark, R.
    As a result of the growing demand for highly customized and individual products, companies need to enable flexible and intelligent manufacturing. Cyber-physical production systems (CPPS) will act autonomously in the future in an interlinked production and enable such flexibility. However, German mid-sized plant manufacturers rarely use virtual technologies for design and validation in order to design CPPS. The research project Virtual Commissioning with Smart Hybrid Prototyping (VIB-SHP) investigated the usage of virtual technologies for manufacturing systems and CPPS design. Aspects of asynchronous communicating, intelligent- and autonomous-acting production equipment in an immersive validation environment, have been investigated. To enable manufacturing system designers to validate CPPS, a software framework for virtual prototyping has been developed. A mechatronic construction kit for production system design integrates discipline-specific models and manages them in a product lifecycle management (PLM) solution. With this construction kit manufacturing designers are able to apply virtual technologies and the validation of communication processes with the help of behavior models. The presented approach resolves the sequential design process for the development of mechanical, electrical, and software elements and ensures the consistency of these models. With the help of a bill of material (BOM)- and signal-based alignment of the discipline-specific models in an integrated mechatronic product model, the communication of the design status and changes are improved. The re-use of already-specified and -designed modules enable quick behavior modeling, code evaluation, as well as interaction with the virtualized assembly system in an immersive environment.
  • Publication
    Ontologiebasierte Datenintegration für das Modellbasierte Systems Engineering
    ( 2015)
    Woll, R.
    ;
    Hayka, H.
    ;
    Stark, R.
    Im Modellbasierten Systems Engineering werden verschiedene Modelltypen wie Anforderungs-, Funktions- oder Systemstrukturmodelle miteinander verknüpft. Da diese unterschiedlichen Modelltypen oft in unterschiedlichen IT-Systemen verwaltet und bearbeitet werden, ist ein geeigneter Datenintegrationsansatz vonnöten, um Verknüpfungen zwischen den verteilten Daten anlegen und verwalten zu können. Ein möglicher, bisher kaum in der industriellen Praxis evaluierter Ansatz dafür ist die Ontologiebasierte Datenintegration. Da dieser Ansatz einige potentielle Vorteile gegenüber anderen Datenintegrationsansätzen verspricht, hat sich das EU-geförderte Forschungsprojekt iProd zum Ziel gesetzt, ihn am Beispiel konkreter industrieller Anwendungsfälle einzusetzen und zu evaluieren. In diesem Beitrag wird ein Überblick über die Erfahrungen und Erkenntnisse aus dem Projekt gegeben und eine Bewertung des Ansatzes vorgenommen.
  • Publication
    Providing product-service-systems - The long way from a product OEM towards an original solution provider (OSP)
    ( 2015)
    Schnürmacher, C.
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    Hayka, H.
    ;
    Stark, R.
    Product-Service-Systems (PSS) have gained tremendous attention in research and industry over the past years. Manufacturing firms transform from providing pure products towards providing integrated products and services. This development is triggered by the increasing customer demand for PSS and the opportunity of manufacturers to differentiate themselves from their competitors as services are hard to replicate. For providing PSS companies need to go through fundamental changes which range from organizational adaptions within the company structure over novel development processes to improving the customer relationship. In this paper the authors describe requirements for providing PSS which were derived from a case study with a crane manufacturer and an extensive literature research. These requirements are considered with respect to the different PSS business models related to the PSS types defined by Tukker. Furthermore the implementation of one of these requirements in the case company is described.
  • Publication
    Simulation of product-service-systems piloting with agent-based models (outlined revision)
    ( 2015)
    Wrasse, K.
    ;
    Hayka, H.
    ;
    Stark, R.
    Product-service systems (PSS) can improve sustainability in terms of responsibility of providers and intensified customer-provider relationships. Therefore, a PSS approach has been applied on the distribution of solar home systems in rural areas of emerging countries to improve quality and increase confidence in this technology. However, many innovative projects fail at the piloting stage because of insufficient validation before implementation. Validation methods for PSS like an integrated gap model (e.g. identification of gaps between deliverables and customers expectations) or interdisciplinary design reviews show its limits on the interdependences between product and service development. A new approach to test PSS involves agent-based simulation models and is presented within this paper. Among system dynamics and discrete event simulation, an agent-based simulation is able to work with less quantitative data and a more detailed view on individual entities than the alternative approaches. Thus, it is possible to create more realistic simulation models to validate especially resource planning of a PSS. Agent-based simulation is used within the MEVIS (Micro Energy Supply Information System) project to model a network of solar home systems which are controlled by remote monitoring in order to improve service processes, e.g. maintenance and repair operations. The pilot test should be carried out efficiently by the preceding virtual validation in the form of a simulation, which is built in NetLogo, a tool that enables modeling of a multi-agent environment. Within this environment, communicating technical artifacts as well as different groups of actors are mapped as agents. As a result, diagrams of relevant parameters like the overall repair costs or the estimated customer's satisfaction are displayed and the resource planning is visually supported. This helps to push a PSS into a new market, where you have to deal with existing resources that must be used efficiently. The contributions in this paper provide the conception and an exemplary presentation of the simulation run.
  • Publication
    Design and manufacturing of a sustainable pedelec
    ( 2015)
    Buchert, T.
    ;
    Steingrimsson, J.G.
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    Neugebauer, S.
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    Nguyen, T.D.
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    Galeitzke, M.
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    Oertwig, N.
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    Seidel, J.
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    McFarland, R.
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    Lindow, K.
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    Hayka, H.
    ;
    Stark, R.
    To facilitate the transition towards sustainable manufacturing, current practices and mechanisms for value creation need to be reconsidered along the whole product lifecycle. However, academic research on sustainability is still bound to narrow fields of applications. In this study, a multi-disciplinary research project is presented that focuses on the development of a sustainable pedal electric cycle (Pedelec) from a first idea to a ready-to-use prototype. The results of the project show how different scientific approaches for bottom-up improvement can be applied together in a concrete case. A holistic view on the product lifecycle proved as a meaningful framework for that purpose.
  • Publication
    Interdisciplinary function-oriented design and verification for the development of mechatronical products
    ( 2011)
    Stark, R.
    ;
    Hayka, H.
    ;
    Figge, A.
    ;
    Woll, R.
    Mechatronical products integrate components that are developed by different fields of engineering and combine them in order to provide new functionalities. The main challenge is the ever increasing complexity and the required degree of interdisciplinarity. The joint research project MIKADO adressed this demand by integrating domain specific development methods and tools into a more systems-engineering-oriented approach. Special emphasis has been placed on the early phases of product development in order to facilitate an early coordination between mechanical, electronical and software engineers and to provide them with easy means for the functional verification of virtual product models. The MIKADO cooperation platform will improve and accelerate the planning and execution of mechatronical product development projects. Interfaces for connecting commercial engineering tools to the cooperation platform guarantee the industrial applicability of the MIKADO solution in connection with existing system landscapes. This reduces investment costs and makes the MIKADO solution attractive, especially to SMEs. The enhancements of the FOD modeler help to collect and manage all requirements of a mechatronical product as well as to define and depict their connections. Their continuous connection to functions, parts and CAD models allows for cross-checking the fulfillment of several geometric requirements. Specific tests for functional and geometric analysis complete the Functional mock-up. They are started from and their results are managed directly in the FOD modeler as well as on the cooperation platform and thus make a continuous review of the products' degree of maturity possible. The methodology for combining a comprehensive requirements management with a functional mock-up for the verification of requirements will be the basis for further research. In addition, the results of MIKADO are planned to be used for commercial products, which will be sold by the project partners.
  • Publication
    Nachhaltige Produktentwicklung: Eine interdisziplinäre Herausforderung
    ( 2011)
    Woll, R.
    ;
    Hayka, H.
    ;
    Lindow, K.
    ;
    Stark, R.
    Eine nachhaltige Produktentwicklung muss darauf abzielen, ein Produkt zu entwickeln, welches über seinem gesamten Lebenszyklus hinweg Nachhaltigkeitsforderungen erfüllt. Da ein Produktentwickler alleine diesen nicht ausreichend überblicken kann, muss die Konzeption und Gestaltung eines Produkts in interdisziplinärer Zusammenarbeit mit Experten aus anderen Fachgebieten durchgeführt werden. In dem Projekt "Methodische Nachhaltigkeitsbewertung von Maschinenkomponenten im Entwicklungsprozess" wurde eine Methodik entwickelt, bei der Produktentwickler, Prozess- und Nachhaltigkeitsexperten gemeinsam dazu beitragen, Gestaltungsalternativen für ein Produkt bezüglich ihrer Nachhaltigkeit bewertbar zu machen.
  • Publication
    Nachhaltige Produktentwicklung - eine inderdisziplinäre Herausforderung
    ( 2011)
    Woll, R.
    ;
    Hayka, H.
    ;
    Lindow, K.
    ;
    Stark, R.
  • Publication
    Virtuelle Produktentstehung in der Automobilindustrie
    ( 2011)
    Stark, R.
    ;
    Hayka, H.
    ;
    Israel, J.H.
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    Kim, M.
    ;
    Müller, P.
    ;
    Völlinger, U.
    Virtualisierung der Produktentstehung trägt entscheidend zur Kostenreduktion, zur Verkürzung der Produktentstehungszeiten sowie zur Steigerung der Produktqualität bei. Die Automobilindustrie hat frühzeitig diese Vorzüge erkannt und setzt verstärkt Methoden und Technologien der Virtuellen Produktentstehung (VPE) ein. In diesem Artikel werden die Methoden und Vorgehensmodelle der Virtuellen Produktentstehung dargestellt und Unterschiede und Anknüpfungspunkte zu denen der Softwareentwicklung herausgearbeitet. Der Artikel beschreibt zunächst die Phasen der Virtuellen Produktentstehung samt der zu verarbeitenden Informationen und der eingesetzten Werkzeuge (z. B. CAx, PDM). Anschließend werden die Entwicklung, die Erprobung sowie die Arbeitsvorbereitung (hierbei insbesondere die Digitale Fabrik) detailliert und relevante Informationen und Werkzeuge vorgestellt. Das Vorgehen wird mit Beispielen aus der Automobilindustrie unterlegt. Der Artikel schließt mit der Darstellung kurz- und mittelfristig zu erwartender Entwicklungen der Virtuellen Produktentstehung.
  • Publication
    PLM-basierte Innovationsbeschleunigung für die mechatronische Produktentwicklung
    ( 2011)
    Stark, R.
    ;
    Hayka, H.
    ;
    Damerau, T.
    Zur Effizienzsteigerung der innovativen interdisziplinären Produktentstehung ist die methodische und werkzeugtechnische Unterstützung eines durchgängigen Systems Engineering (SE), ausgehend von der Innovationsidee, erforderlich. Hierfür bietet die Product Lifecycle Management (PLM)-basierte Gestaltung des Innovationsprozesses in enger Kopplung mit dem Produktentstehungsprozess ein großes Potenzial an. Vorgestellt werden Ansätze für die Optimierung von SE-Prozessen sowie Best Practice Referenzprozessmodelle für das Innovationsmanagement. Ein Schwerpunkt bildet die PLM-integrierte Umsetzung des Referenzprozesses, die exemplarisch anhand einer Werkzeugintegration zwischen Wissens- und Produktlebenszyklusmanagement dargestellt wird. Entlang eines Anwendungsfalls wird die Überführung von Innovationsideen in eine PLM-Lösung und deren Verknüpfung mit der Produktstruktur demonstriert. Die Implementierung basiert auf einer flexiblen serviceorientierten Architektur und der Standardschnittstelle OMG PLM-Services 2.0.