In multi-site assembly, problems such as defective tools often cause delays. In order to avoid deferred deliveries and increased costs, assembly control is required to promptly determine a new assembly plan. A research project aims to develop a software support system which assists assembly control in the replanning process by applying online simulation to quickly identify possible plan alterations and evaluate their expected impact on logistical key figures.
assembly control, simulation, production planning and control, failure management
In this paper the development of the new production technology hybrid forging is described. Hybrid forging combines forming of bulk and sheet metal-elements including joining. Using three model experiments the joining by material bond and by form closure is analyzed. The form closure works like a riveting and the experiments showed good results. But not in every area of the specimen a material bond was present.
hybrid, forging, sheet metal forming, joining technology, steel, adhesive bond
The strength/density ratio of aluminium can be increased significantly by the integration of ceramic particles in the metal matrix, so called Aluminum MMC. Because machining of MMCs is very expensive due to the high hardness of the ceramic particles precision forging of Aluminum MMCs allows the high quantity production of near net shape components with a strength/density ration. The paper describes the development of a precision forging sequence for a demonstration made of Aluminum MMC.
aluminium metal matrix composites, flashless forging, FEA
In a research project by the Institut für Integrierte Produktion Hannover (IPH) and the Institute of Metal Forming Siegen the basics for hydroforming titanium tubes were investigated. The aim of this research project was to develop a multi-stage process chain for hydroformed parts made of titanium. First the method-specific material properties as well as the tribological system were examined. The results were combined in a simulation model which enabled the process development. Finally, the developed process chain was successfully tested using a real component and the trials were compared with the simulation results.
hydroforming, FEA, titanium
Due to high mechanical loads the die cavity shows high wear in warm forging processes. Within this paper the ability of a hydrogenated amorphous carbon doped by 40 % chromium as wear protective coating for bulk forming processes will be analysed. Therefore billets with temperatures between 650 and 1200 °C have been forged on this layer. Thereafter the layers are analysed and the wear behaviour is evaluated.
coating, forging, forming
The early detection of defects in forged parts offers economical advantages due to the possibility of sorting them out of the process chain. The detection of defects during the forging process is not state of the art. Due to the rough conditions in forging (e. g. high temperatures and forces) the integration of sensors monitoring the forging process is hardly viable. Usually defects of forged parts – which are not obvious and can therefore hardly be identified by the press user – are detected by measurements after cooling or later by the customer. In both variants costs occur. Within the presented research project an in-situ forging process monitoring is developed which works without sensors and shows results directly after forging.
metal, steel, metal processing, forging, quality
The early detection of defects in forging processes offers economic benefits. For example, workpieces that are forged incorrectly can be discharged from the process chain immediately and thus do not cause additional process costs, i. e. in a subsequent heat treatment. The development of a novel process monitoring using electrical current allows the identification of forging defects and underfillings.
forging, process monitoring
The higher mechanical loads in warm forming processes lead to increased mechanical wear of the dies. Using hard Diamond-like Carbon (DLC)-coatings can reduce this main disadvantage of warm forging. By an adequate doping of DLC with elements the temperature stability of these coating can be increased. Especially in areas with high relative movement the analysed coatings show advantageous behaviour compared to not coated dies.
diamond-like carbon (DLC), warm forming, bulk forming, wear
Forged parts have geometrical fluctuations for example caused by die wear. The investigation of a controlled, movable flash gap by FEA for compensation purpose showed how far the material flow can be varied during the forming operation. A potential to improve forging results is derived.
forging, die design, material flow, FEA, flash land
Hydroforming is often used to conduct forming of thin-walled hollow parts made of tubes. In order to form thick-walled hollow parts made of Aluminum a process has been developed, to form such parts. These parts are in a heated state. The forming has been made by help of an active fluid medium on a hydraulic deep-drawing press. For investigation purpose an example process has been designed for a trial part. This process has been analyzed by FEA and verified by laboratory tests.
hydroforming, forging, tubes, aluminium, FEA
Manufacturing companies of xxl products are increasingly forced to distinguish themselves from their competitors by the production costs. Commonly used manufacturing principles are designed for a customized production with high product variety. However, with regard to the production costs these manufacturing principles are insufficient. The transfer of alternative manufacturing principles to the xxl production offers a promising approach to increase the productivity.
flow-production, xxl goods, reorganization, manufacturing principles, prefabrication
Stocks enable a defined service degree even at varying demands. Shortterm changes of the demand behavior can, however, cause missing part situations. In case the production is able to adapt the amount of production to a changed demand situation at short notice, the delivering ability can remain unchanged. At stochastic demands the right time of the change of amounts of production is a central question.
production quantities fluctuating demands, degree of service, delivery capability
Economic environments that are becoming more and more turbulent demand a rising schedule and quantity flexibility from companies. To achieve simultaneously a high economic efficiency a high amount of load flexibility on the shop floor is required. By which factors the existing amount of load flexibility in a production is influenced and how it can be measured is not answered yet. To bridge this gap an actual research project aims towards developing a method to quantify load flexibility in a production.
work load flexibility, work load smoothing, work load scattering, production control method, product
The product design already determines 70% of the future product costs. Therefore, the structural design offers a promising approach for reducing the lifecycle costs of an airplane. An essential design parameter is the decision between a monolithic or modular construction. The current design of aircraft wings can be described as largely monolithic; the basic structure consists of a small number of undivided components. For example the top cover of the Airbus A350 wing consists of a single component with a length of 32m. For the production of these large scaled components production machines, e.g. autoclaves, with very huge dimensions are needed. However other aircraft parts such as the fuselage are not one-piece components. The fuselage is composed of several fuselage modules, which are pre-equipped and then riveted together. In this paper, a small-scaled modular design for airplane wings is presented and the technical feasibility is discussed. Moreover, we identified modularization factors which significantly influence the decision between a monolithic or modular construction.
structural design, large scaled products, modular design
This paper describes methods and solutions for transferring cognitive abilities such as recognition, communication, orientation, learning and planning to transport systems. The implementation of these abilities is carried out by means of optical technologies as shown in application examples. Small scalable conveyor modules can be applied in the field of warehousing to specific nodes of the material handling system to enhance the spectrum of feasible logistic operations, as well as to increase the overall system flexibility. 3D camera systems integrated in the forks of an industrial truck can acquire an image of the front end of the forks. Custom algorithms then detect the position of pallets and storage locations. Thus, assistance can be given during the loading/unloading procedure. Additionally, the vehicle determines its position using optically networked beacons. Positioning enables tracking and tracing of loading units and on-board navigation. Cognitive abilities, supported by optical technologies, can be transferred to other aspects of transport systems. Decentralized networking modules allow a continuous information flow between distinct transport systems. Thus, other cognitive abilities such as decentralized routing of products can be effectively
cognitive transportsystem, optical technology, optical position determination
Logistics is an essential part of the value chain. Therefore, sustainable logistics systems are a decisive competitive and success factor for companies. Through individual customer requirements, shorter innovation cycles and an increasing variety of product types, the requirements have become increasingly complex in the material handling engineering sectors. To meet these requirements and to allow a continuous increase in efficiency of logistics systems, the development of innovative systems is necessary. A key to the design of such systems is the use of optical technologies. Using a simplified scenario the possibilities of optical technologies in intralogistics are represented in this paper.
materials handling, optical communication, optics, intralogistics
In the research project ISI-WALK methods and technologies for the efficient design and economical operation of supply chains have been developed. These methods and technologies are helping to enable logistic systems to adept to different materials and information flows. On the basis of the the human cognitive abilities and the resulting high mutability logistic systems shall be enabled to recognize their surroundings, to communicate relevant information and to learn or plan autonomously. The technical results are divided into four sub-goals: a system based on 3D camera technology assistance system for trucks, a system for optical position detection in industrial environments, a versatile coordinate-based warehouse management system and a method for planning and evaluation of the major driving forces. The research project was funded within the framework concept "Research for the industry of tomorrow" by the Federal Ministry of Education and Research (BMBF).
optical positioning, active infrastructure, data transmission, signal processing, image processing
In general, XXL-Products consist of many different parts which are often individually produced using various manufacturing technologies. Companies collaborate in production networks while focusing on their core competencies. In order to realize an evaluation and improvement of the network’s logistical maturity level and thus the logistical efficiency, a maturity-level-based development guideline is needed.
supply chain management, supplier evaluation, production networks, logistical performance, maturity
Innovative developments often result from the knowledge generated in the lifecycle of existing products. Following this approach in a current research project engineers of IPH develop methods and tools for the acquisition and utilization of knowledge from the entire product lifecycle.
product lifecycle, knowledge management
A central control of automated guided vehicle systems (AGVS) doesn’t longer satisfy the require-ments of a versatile production. With procedures from the field of artificial intelligence a control can be decentralized and made more flexible. In this way the tasks of the central control can be distributed to different entities in the system. Thus the complexity of the tasks is reduced. The present article deals with the decentralization of the AGVS control and focuses on the order allocation, route finding and conflict resolution.
agv, decentralzied control, automated guided vehicles
