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.
    ;
    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
    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
    Providing product-service-systems - The long way from a product OEM towards an original solution provider (OSP)
    ( 2015)
    Schnürmacher, C.
    ;
    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
    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.
    ;
    Oertwig, N.
    ;
    Seidel, J.
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    McFarland, R.
    ;
    Lindow, K.
    ;
    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
    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
    Entwicklungszusammenarbeit koordinieren
    ( 2011)
    Hayka, H.
    ;
    Wolter, L.
  • 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
    Kollaboration-Plattformen für virtuelle Unternehmen
    ( 2010)
    Hayka, H.
    ;
    Langenberg, D.
    ;
    Stark, R.