Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Conceptual Introduction of required development capabilities for Model-Based Systems Engineering
    ( 2021)
    Manoury, Marvin Michael
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    Schmidt, Simon
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    Zimmermann, Thomas C.
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    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
    Towards an AI-Enhanced Circular Economy. AI-enhanced identification, inspection and sorting for reverse logistics
    ( 2020)
    Schlüter, Marian
    In terms of circular economy, remanufacturing ensures a high level of value recovery. After each life-cycle used products are returned to a remanufacturer for identification, inspection, sorting and reprocessing, ensuring the required quality for a next life cycle. This talk presents the project EIBA, funded by the German Federal Ministry of Education and Research, in which concepts to improve identification, inspection and sorting are developed and implemented by enhancing the sorting stations with sensor technology and AI on image and business data. First results show promising progress for AI-based visual recognition of used automotive components, also referred to as "cores".
  • Publication
    Avoidance of End Crater Imperfections at High-Power Laser Beam Welding of Closed Circumferential Welds
    ( 2019)
    Gook, Sergej
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    Üstündag, Ömer
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    Gumenyuk, Andrey
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    Rethmeier, Michael
    The present work deals with the development of a strategy for the prevention of end crater defects in high-power laser welding of thick-walled circumferential welds. A series of experiments were performed to understand the influence of the welding parameters on the formation of the imperfections such as pores, cracks, excessive root-side drop-through and shrinkage cavities in the overlap area. An abrupt switch-out of the laser power while closing the circumferential weld leads to a formation of a hole which passes through the whole welded material thickness. A laser power ramp causes solidification cracks which are initiated on the transition from full-penetration mode to partial penetration. Strategies with a reduction of the welding speed shows a creation of inadmissible root sagging. Defocusing the laser beam led to promising results in terms of avoiding end crater imperfections. Cracks and pores could be effectively avoided by using defocusing techniques. A strategy for avoiding of end crater defects was tested on flat specimens of steel grade S355J2 with a wall thickness of 10 mm and then transferred on the 9.5 mm thick pipe sections made of high-strength steel X100Q.
  • Publication
    What dynamics should impedance-controlled robots render?
    ( 2019)
    Haninger, Kevin
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    Surdilovic, Dragoljub
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    Bastidas Cruz, Arturo
    While impedance control is the standard framework for physically interactive robots, the design choice of what dynamics should be rendered requires additional information (assumptions on environment, in-situ data). The range of dynamics which can be rendered by a robot is informed by its mechatronic design (actuators, physical compliance, innerloop control), and these mechanical design decisions must be made in advance. How can a mechatronic design be evaluated when the system objectives and environment dynamics are not quantified? This paper presents performance metrics proposed for pHRI in literature, and seeks to move towards a unified methodology for mechatronic design on interactive robots: supporting potential performance and safety over a set of environments.
  • Publication
    Hybrid laser arc welding of 25 mm thick materials using electromagnetic weld pool support
    ( 2018)
    Üstündag, Ömer
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    Avilov, Vjaceslav
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    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    In addition to the many advantages of deep penetration, increased welding speed and a low sensitivity to manufacturing tolerances such as gap and edge offset, the hybrid laser arc welding process is used increasingly in industrial applications such as shipbuilding or pipeline manufacturing. Nonetheless, thick-walled sheets with a wall thickness of 20 mm or more are still multi-pass welded using the arc welding process, due to increased process instability by increasing laser power. Welding at reduced speed, especially in a flat position, leads to an irregular formation of the root part such as dropping. The hydrostatic pressure exceeds the surface tension, which decreases with increasing seam width. In order to prevent gravity drop-outs, the use of a melt pool support is necessary. Usual weld pool supports such as ceramic or powder supports require time-consuming mechanical detachment. The electromagnetic weld pool support system, which is described in this study, operates without contact and based on generating Lorentz forces in the weld pool. An externally applied oscillating magnetic field induces eddy currents and generates an upward directed Lorentz force, which counteracts the hydrostatic pressure. This allows single-pass welds up to 25 mm by hybrid laser arc welding process with a 20-kW fibre laser. Moreover, it is favoured by the diminished welding speed the cooling rate which leads to an improvement of the mechanical-technological properties of the seams - the lower formation of martensite in the microstructure enables better Charpy impact toughness. The electromagnetic weld pool support extends the limitation of the laser hybrid welding process in the thick sheet area. By adapting the electromagnetic weld pool support to the laser and laser hybrid welding process, the application potential of these technologies for industrial implementation can be drastically increased.
  • Publication
    Effect of laser-beam and hybrid-laser-arc welding parameters and filler metal on microstructure and mechanical properties of thick heat-treated steel X8Ni9+QT640 for cryogenic service
    ( 2018)
    El-Batahgy, A-M.
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    Gook, S.
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    Gumenyuk, A.
    ;
    Rethmeier, M.
    The present research work encloses results of experimental investigations of the interaction between welding process parameters for laser-beam and hybrid-laser-arc as well as type of the filler metal and the achievable mechanical properties of the weld joints on steel grade X8Ni9+QT640 for cryogenic service containing 9% nickel. The results obtained contribute to the development and conversion in the industrial practice a new laser beam-based welding technology for the automated manufacturing of facilities for the liquefaction, storage and the transport of natural gases (LNG facilities). The results show, that the martensitic microstructure of the laser weld metal including low amount of retained austenite not exceeding 3.5% leads to the relatively low V-notch impact energy. The remarkable heterogeneity in the chemical composition of the weld metal through the weld thickness could be recognized in the case of hybrid-laser-arc welding with ERNiCrMo-3 austenitic filler metal, what also led to insufficient impact toughness of the weld metall. The most promising results could be achieved by using 11%Ni filler wire, which is similar to the base metal and provides a homogeneous microstructure with uniform distribution of Ni through the weld seam. It is remarkable, that a correlation between Charpy impact toughness and wire feeding speed and respectively process heat input exists. The highest toughness values were 134±58 J at -196 °C. The both laser as well as laser-hybrid welds passed the tensile test. The failure stress of 720±3 MPa with a fracture location in the base material was achieved for all samples tested.
  • Publication
    Global model and observatory for international responsible research and innovation coordination
    ( 2014)
    Menevidis, Zaharya
    The RESPONSIBILITY project aims to create a Forum and a virtual Observatory in Responsible Research and Innovation (RRI); which facilitates the network of stakeholders to adopt and diffuse a common understanding in RRI between different actors in Europe and around the globe. The RESPONSIBILITY project has the vision to become an effective knowledge transfer tool that diffuses scientific knowledge and simultaneously involves researchers, policy makers as well as societal stakeholders in a user‐friendly manner to the concept and practice of RRI. The strategy for fulfilling this vision is to integrate the RESPONSIBILITY Observatory through an innovative way that will assist the research community to induce their ideas in the RRI concept and practice. Furthermore, it aims to create a critical mass of interested public surrounding and supporting the implementation of RRI, at the researchers' daily work, in their individual context. RESPONSIBILITY project was launched on 1st February 2013, for three years' implementation, brings together 10 partners from 8 European countries as well as 3 partners from Asia and America and targets these following outcomes: BL The project will have an extensive societal, economic and scientific impact and it will particularly enhance the International Coordination in the field of RRI, and spread results of best practices of technologies without any discrimination among countries, common European identity and perceived sense of RRI. BL It will enhance networking and collaboration by establishing a virtual place to find the tools for active networking, for dialogue and polls and for on-line discussions to stimulate and respond to issues raised / identified in RRI. BL The project will create an on-line directory facilitating the exchange of information, concepts and approaches on RRI. BL It will establish a critical mass in confronting multi‐dimensional and complicated societal issues. BL RESPONSIBILITY will also promote networks of scientists to facilitate the definition of research priorities, avoiding duplication of efforts and strengthen the collaboration under horizontal issues.