Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Methodology for a reverse engineering process chain with focus on customized segmentation and iterative closest point algorithms
    ( 2022)
    Mönchinger, Stephan
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    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.
  • Publication
    Literature review of quality attributes for collaborative product development
    ( 2022)
    Randermann, Marcel
    ;
    Blüher, Till
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    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.
  • Publication
    Knowledge transfer and engineering methods for smart-circular product service systems
    ( 2021)
    Halstenberg, Friedrich
    ;
    Dönmez, Jasmin
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    Mennenga, Mark
    ;
    Herrmann, Christoph
    ;
    Stark, Rainer
    Smart Product Service Systems (Smart PSS) have the potential to contribute to a Circular Economy (CE), but in the design of these systems engineering teams often lack information and knowledge on CE strategies and processes. Against this background, the authors propose a knowledge transfer system for the design of Smart-circular PSS. The system can be used in the concept phase of the Smart PSS development process and delivers information on CE strategies via a Smart-circular PSS Lifecycle Flowchart (SCPLF) and service archetypes. These strategies can be selected, supplemented and extended according to individual user requirements. The approach was validated using an intelligent street lighting system. This paper summarizes findings from the application and provides insights into potentials and limitations for the design of Smart-circular Smart PSS.
  • 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
    Automated 3D scan based CAD-repositioning for design and verification in one-off construction
    ( 2021)
    Mönchinger, Stephan
    ;
    Schröder, Robert
    ;
    Stark, Rainer
    The presented engineering discipline one-off construction is characterized by a multiplicity of manual processes. As almost all modern product developments, the manufacture is based on the creation and consistent use of digital models. Quality of underlying data can vary greatly and it is not certain that digital models match the actual state of construction. This can result in the need for rework after production or installation. Especially challenging in the area of premium products, for which high quality, scarce materials are used and tight schedules are defined. If physical products are reworked, the corresponding digital models must be manually maintained. At present, attempts are being made to counteract these late adjustments by means of physical mock-ups or visual inspection of 3D scan data. Such scan data is used for automated adaptation of underlying digital models to the actual state of the physical construction. Existing Point Cloud Library functionalities were adapted and further algorithms were designed. The developed software backend was integrated into the existing software architecture. During the software development, great care was taken to ensure that the backend is based on open source content. The results show significant improvements of the data basis for the subsequent engineering activities. This will lead to a significant reduction of manual effort and rework, ensuring development cycles and even shorten delivery times. It reduces costs in the product creation process and sustainably strengthens confidence in digital models used. It has been shown that automation of design processes can have productivity-enhancing effects in one-off construction.
  • Publication
    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.
  • Publication
    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.
  • Publication
    User centered development of a digital twin concept with focus on sustainability in the clothing industry
    ( 2020)
    Riedelsheimer, Theresa
    ;
    Dorfhuber, Lisa
    ;
    Stark, Rainer
    The optimization of a product's socio-economic and environmental impact is gaining more relevance for customers and regulating institutions. Still, there is a gap between sustainable attitude and behavior. In this context, new technologies are explored to stimulate sustainable consumers' behavior. This paper aims at analyzing the concept of a Digital Twin and its sustainability impact. The authors present a user centered development of a Digital Clothing Twin with the aim to foster sustainability in the Mid-of-life and End-of-Life-phase. The sustainability impact of the Digital Twin concept as a potential solution as well as part of the problem is discussed.
  • Publication
    Natural Virtual Reality User Interface to Define Assembly Sequences for Digital Human Models
    ( 2020)
    Geiger, Andreas
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    Brandenburg, Elisabeth
    ;
    Stark, Rainer
    Digital human models (DHMs) are virtual representations of human beings. They are used to conduct, among other things, ergonomic assessments in factory layout planning. DHM software tools are challenging in their use and thus require a high amount of training for engineers. In this paper, we present a virtual reality (VR) application that enables engineers to work with DHMs easily. Since VR systems with head-mounted displays (HMDs) are less expensive than CAVE systems, HMDs can be integrated more extensively into the product development process. Our application provides a reality-based interface and allows users to conduct an assembly task in VR and thus to manipulate the virtual scene with their real hands. These manipulations are used as input for the DHM to simulate, on that basis, human ergonomics. Therefore, we introduce a software and hardware architecture, the VATS (virtual action tracking system). This paper furthermore presents the results of a user study in which the VATS was compared to the existing WIMP (Windows, Icons, Menus and Pointer) interface. The results show that the VATS system enables users to conduct tasks in a significantly faster way.
  • Publication
    Issues in distributed Engineering of SMEs over the Collaboration Life Cycle
    ( 2020)
    Blüher, Till
    ;
    Randermann, Marcel
    ;
    Rosa, Maiara
    ;
    Stark, Rainer
    ;
    Jochem, Roland
    Collaboration in product development has played an increasingly important role in the past decades. However, distributed engineering creates a wide variety of challenges that, in some cases, are highly context dependent. In Germany, small and medium sized enterprises (SMEs) play a vital role to the economy and engage in many collaborative engineering projects. So far, it remains a practical challenge to design a joint engineering environment that is not well-assisted by the science community. In addition, collaborations evolve over time. This study examines problem fields in collaborative engineering of SMEs and presents the collaboration life cycle (CLC) framework. This framework aims at classifying and contextualizing different problem domains within the greater context of a collaborative partnership. Therefore, we have conducted an interview study with industry experts regarding challenges in distributed engineering with SMEs and validated the results through an industry workshop. We argue that a high-level perspective on collaboration with different life-cycle phases in conjunction with the description of practical problem fields can assist in understanding collaboration in distributed design better. Going forward, the findings provide the base for ongoing research in a project that aims to make the maturity level of any distributed engineering environment assessable and provides guidance for improvements.