The precision forging is energy and time saving. Therefore the basics of this topic are presented. On the one hand the material characteristics as temperature and yield stress development are shown. On the other hand tool geometry and construction instructions are given. Beyond these topics the principles of FEM, reachable tolerances are presented. Different types of crankshafts, a gear wheel and a pinion shaft are examples that were successfully investigated and even party produced in industrial environment. The goal of this chapter is to show the basic knowledge of precision forging.
precision forging, flashless
In this paper, a novel, widely usable gripper system for craneless and weather-independent assembly of rotor blades for offshore wind turbines is presented. This gripper system was developed in the context of the research project "XXL Assembly aids" of the IPH - Institute of Integrated Production Hannover gGmbH.
assembly aid, wind energy plan, xxl-products
In this article, a novel approach for an optical tracking system is presented, which is used in addition to the positioning of industrial trucks in particular the tracking and storage of the position data of carriers in intralogistics. The locating system consists of an active optical infrastructure and a receiving unit .
optical positioning system, indoor navigation
Growing XXL products reach dimensions that are no longer manageable by humans without innovative technological support. Therefore (semi-)automated assembly aids for the final assembly of large components are needed. The assembly of XXL-products is similar to the construction of prototypes. The aim is to avoid redundant new developments and designs of installation aids and to make them available across processes. In addition to presenting a method to systematize and select the right installation aid, the development of a gripper system for craneless and thus weather-independent assembly of rotor blades for offshore wind turbines is shown in this paper.
assembly aid, wind energy plan, xxl-products
In the research project "IdentOverLight" a new Auto-ID system ,using visible light communication, was developed. The new label combines the advatages of existing Auto-ID systems. It is rewriteable like RFID, machine-readable like Barcodes and readable by human like labels.
auto-id, rfid, qr-code, visible light communication
The main idea to develop an individual production is trend-setting and a part of the future project "Industry 4.0". Apart from the optimization of the manufacturing and delivery time there will be a focus on elevated information. Therefore the production systems of the future have to live up to requirements like the mutability, the real-time and network capability. A specific trial is based on the idea to port the cognitive features of a human to the production systems.
cognition,production systems, flow of information, human-machine interaction
Automated guided vehicle systems (AGVS) are a vital component for efficient production systems in connection to intra logistics and essential for parts of the internal material handling, so they could not imagine living without them. The essential function of an AGVS is to control the automated guided vehicles (AGV), which are able to provide with application-specific load handling devices like telescopic forks or lifting tables, automatically. AGV could be used in different parts of applications like for example the transport of pallets, assembly or commissioning. The motivation of this project is to develop a new market for competitive autonomous transport systems. Economic forklifts should be created by technological development to handle logistical subtasks, like transferring goods, commissioning and transporting, autonomously.
driverless transport systems, driverless transport vehicles, autonomous, 3d camera technology, voice
A xxl-product is defined as product, whose production costs increase disproportionately in relation to further growth of a characteristic product feature. Existing models of supply chain design are not designed for xxl-products. For this reason a method was developed to create a supply chain for a xxl-product. The supply chain design works in due consideration of the most relevant xxl-product specific features. The created supply chain can be evaluated for their logistical quality. Therefore a comparison between different supply chain variants is possible.
xxl-product, supply chain design, logistical objectives
The assembly of complex, large-scale products is often characterized by poor date availability, limited process standardization, frequent product modifications and flexible usage of resources, which often leads to interruptions in the assembling process. Therefore, in a research project between the IPH Hannover and the WZL of RWTH Aachen University, a methodology for assembly processes is developed which allows the identification and evaluation of process alternatives in case of interruptions. For the evaluation of those process alternatives logistical objectives are used.
xxl-product, adaptive assembly scheduling, interruption assembly process, logistical objectives
In this study two approaches in automotive lightweight construction have been combined: weight reduction based on material and based on structural design. Steel and aluminum are used for the first approach, and hydroforming is the method for design optimization by shaping. Steel and aluminum show different forming behaviors due to their characteristic yield stresses. The challenge in developing a hydroforming process for THTs is to provide feasible forming conditions for both the steel and the aluminum part. Forming tests were carried out on sheet metal specimens of laser brazed and laser soldered steel and aluminum to investigate the impact of specific parameters and to analyze the joint area’s forming behavior. An FEA simulation was set up in order to design a tube hydroforming process for THTs of laser joined steel and aluminum. Eventually, the hydroforming process for THTs will be designed and executed.
hydroforming, automotive, laser brazing, laser soldering, steel-aluminum, car body, engine downsizin
The project REFoCh is about resource efficient forging of complex high duty parts, e.g. crankshafts. Within this project founded by the European Union, a new process chain for a crankshaft will be developed with the aim of reducing the flash quota significantly. In the conventional forging sequence, 54 % flash occur, the aimed flash quota is 15 %. To reach this objective, a multidirectional forging step will be implemented in the new process chain in order to reduce the material significantly.
flash reduced, multidirerectional forging, cranskshafts
The material costs represent up to 50 % of the total production costs. By decreasing the flash ratio the material usage and production costs in forging operations can be reduced. For complicated forging parts the development of a new forging sequence is necessary to achieve a flash reduced forging sequence. This development was performed for a two-cylinder crankshaft. The new flash reduced forging sequence is using flashless preforming operations, an induction reheating of the preformed complicated work piece and a flash reduced final forging. With the reduction of the flash ratio from 54 % down to 10 % the total energy consumption was reduced and the competitive capacity of forging SME’s is increasing.
flash reduced, process chain, crankshaft, induction heating
Data analysis on a microcontroller in the immediate vicinity of the measuring point creates an intelligent sensor node that enables a condition prognosis of gearbox components. The IPH compares different approaches of analysis regarding computing time and energy consumption in order to minimize the effort of wireless data transmission.
condition monitoring, wireless sensor nodes, microcontroller
The production ramp-up is often a critical period for manufacturing companies. It is essential to prepare an efficient plan and to monitor consistently the abidance of this plan. Generally processes and activities can be monitored with key performance indicators. This article describes an approach to identificate key performance indicators for the monitoring of additional production capacities at new locations.
production ramp-up, maturity model, aggregation logic, ramp-up management
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, Industrie 4.0 was presented as a major focus of current research.
industrie 4.0, automation technology, logistics
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, the challenges regarding the production of large-scale products were presented as a major focus of current research.
xxl products, large-scale products, production technology, logistics, automation technology
The lecture introduced IPH – Institut für Integrierte Produktion Hannover gGmbH with its three fields of activity: forming technology, logistics and automation technology. Furthermore, research and consulting projects were discussed. In addition, the challenges regarding leadership within lean enterprises were presented as a major focus of current research.
lean production, lean management, leadership
