Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    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.
  • Publication
    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.
  • 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
    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.
  • Publication
    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.
  • Publication
    Conceptual Introduction of required development capabilities for Model-Based Systems Engineering
    ( 2021)
    Manoury, Marvin Michael
    ;
    Schmidt, Simon
    ;
    Zimmermann, Thomas C.
    ;
    Stark, Rainer
    In the last years, multiple tools and methodologies have emerged that try to support the engineers to conduct Model Based Systems Engineering (MBSE). Nevertheless, the tools are usually bound to a certain methodology, which often requires sequential steps instead of supporting the iterative character of modern product development. In this paper, we conceptually introduce the development capabilities of the 5D model for MBSE as a convenient way to cover all relevant aspects of MBSE in an iterative way while being open to methodology and tool choice.
  • Publication
    Concept and Architecture for Information Exchange between Digital Twins of the Product (CPS) and the Production System (CPPS)
    ( 2021)
    Vogt, Anna
    ;
    Müller, Ralph Klaus
    ;
    Kampa, Thomas
    ;
    Stark, Rainer
    ;
    Großmann, Daniel
    The Digital Twin concept and CPS- and IIoT-based approaches are increasingly important topics concerning future Industry 4.0 architectures. They offer high potential for dynamical aspects in intelligent production planning and control as well as part traceability and documentation. Standardized information exchange is an upcoming requirement among the whole supply chain. This paper presents a concept for a Digital Twin architecture based on motor production in the automotive industry. The key aspect is an information exchange structure for Digital Twins of products and production systems that are combined using principles of Dynamic Aggregation.
  • 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
    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.
  • Publication
    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.