STUTTGART CONFERENCE ON AUTOMOTIVE PRODUCTION

Transcription

1 SCIENCE. INDUSTRY. STARTUPS. STUTTGART CONFERENCE ON AUTOMOTIVE PRODUCTION BOOK OF Pre-Week 2-9 November 2020 & Virtual Conference 9-10 November 2020 scap2020.arena2036.de

2

3 Stuttgart Conference on Automotive Production 9-10 November 2020 Version October 5, 2020 Dr.-Ing. Frieder Heieck Dr.-Ing. Philipp Weißgraeber Manuel Fechter David Korte Research Campus ARENA2036 Pfaffenwaldring Stuttgart scap2020.arena2036.de

4 4

5 Contents Preface 7 Scientific Committee 9 Overview of the Scientific Sessions 11 Scientific Sessions 19 Session 1: Next Generation Automotive Production Session 2: Data Management & Interoperability Session 3: Manufacturing Technologies Session 4: Logistic Concepts and Enabling Technologies Session 5: Sustainability & Energy Efficiency in Production Session 6: Body in White & Painting Session 7: Smart Systems & Services in Manufacturing List of all authors 87 Note: Please note that the presented titles, abstracts and contributing authors in this book of abstracts might deviate from the final paper contributions published in the SCAP2020 conference proceedings. 5

6

7 Preface Welcome to the 1 st International Stuttgart Conference on Automotive Production! As the Covid-19 pandemic is still holding sway, SCAP2020 will be held as a fully virtual conference on November 9 and 10, The theme of this years conference is Next Gen Automotive Production Sustainability through Reconfigurability. In the past years, great efforts have been made to realize versatile and resilient production environments, which are able to adapt rapidly to new requirements and product variations on a daily basis. Next to economic advantages, current times also and maybe more than ever demand that ecological and social aspects are taken into account when defining technological objectives. With this years theme, we would like to address both aspects and invite the audience to reflect on technology from a broader perspective. In seven sessions, SCAP2020 presents advances in next generation automotive production, data management & interoperability, manufacturing technologies, logistic concepts and enabling technologies, sustainability & energy efficiency in production, body in white & painting, as well as smart systems & services. Host of the conference is the Research Campus ARENA2036 in Stuttgart, Germany a publicly funded Initiative of the Federal Ministry of Education and Research. The conference is supported by our collaboration partners Fraunhofer IPA, the University of Stuttgart and STARTUP AUTOBAHN as well as our knowledge partner IEEE TEMS. With the new conference format, we want to mirror the broad and interdisciplinary environment of ARENA2036 and present you innovative solutions by automotive R&D departments, research institutes and startups to provide insight into current fields of action for automotive value creation. In addition to more than 50 highly relevant scientific papers contributed by researchers and developers from academia and industry, the conference presents challenges and visions of future automotive production environments in four excellent keynote speeches. Moreover, six international startups will showcase their products and solutions in a separate pitch session. Videos of all scientific contributions are available online one week prior to the conference, so that attendees have enough time to select and view their contributions in advance. During the live conference, all guests are able to interact with the speakers in order to discuss their work and 7

8 Preface exchange ideas. We are very grateful for the support of our distinguished experts from the international Scientific Committee, who made great efforts to select excellent contributions and improve the quality of papers by intensive peer reviews. We have gathered all the abstracts from the conference into this book to provide an overview of the scientific contributions allocated to seven conference sessions. We hope that you enjoy this first episode of the SCAP conference series and wish you an interesting reading and fruitful discussions. Your local organizing team of SCAP2020 David Korte Institute of Mechanical Handling and Logistics, University of Stuttgart Manuel Fechter Fraunhofer Institute for Manufacturing Engineering and Automation IPA Frieder Heieck ARENA2036 Research Campus Philipp Weißgraeber ARENA2036 Research Campus 8

9 Scientific Committee We would like to thank all members of the scientific committee for their great support in arranging the conference and for their insightful reviews. We are fortunate to have a scientific committee that stands out due to its professional excellence and that simultaneously represents the interdisciplinary character of the conference as a whole. Prof. Dr.-Ing. Thomas Bauernhansl Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Germany Prof. Lionel Birglen Robotics Laboratory, Polytechnique Montréal, Canada Prof. Dr. Alexander Brem Prof. Dr.-Ing. Johannes Fottner Prof. Bronwyn Fox Prof. Dr.-Ing. Kai Furmans Prof. Dr.-Ing. Marco Huber Prof. Dr. Jeng-Ywan Jeng Prof. Taeseok Jeong Institute of Entrepreneurship in Technology & Science, University of Stuttgart, Germany Institute for Logistics Engineering, Technical University Munich, Germany Deputy Vice-Chancellor, Research and Enterprise, Swinburne University of Technology, Melbourne, Australia Institute for Material Handling and Logistics, Karlsruhe Institute of Technology, Germany Institute of Industrial Manufacturing and Management, University of Stuttgart, Germany Institute of Mechanical Engineering, National Taiwan University of Science and Technology/Taiwan Tech, Taipeh, Taiwan Ulsan National Institute of Science and Technology, Republic of Korea 9

10 Scientific Committee Prof. Dr.-Ing. Bernd Kuhlenkötter Prof. António M. Lopes Prof. Ole Madsen Prof. Dr.-Ing. Peter Middendorf Prof. Dr. Peter Ohlhausen Prof. Dr.-Ing. Martin Ruskowski Prof. Dr.-Ing. Robert Schulz Prof. Dr. Marcus Strand Prof. Dr.-Ing. Dr. h.c. Michael Weyrich Prof. Ing., D.Sc. Soumaya Yacout Institute for Production Systems, Ruhr University Bochum, Germany Institute of Engineering, University of Porto, Portugal Institute of Materials and Production, Aalborg University, Denmark Institute of Aircraft Design, University of Stuttgart, Germany Fraunhofer Institute for Industrial Engineering IAO, Germany German Research Center for Artificial Intelligence, Kaiserslautern, Germany Institute of Mechanical Handling and Logistics, University of Stuttgart, Germany Course Manager for Computer Science, Baden-Württemberg Cooperative State University (DHBW), Karlsruhe, Germany Institute of Industrial Automation and Software Engineering, University of Stuttgart, Germany Industrial Engineering and Applied Mathematics Department, Polytechnique Montréal, Canada 10

11 Overview of the Scientific Sessions Session 1: Next Generation Automotive Production 1.1 Fries et al. Fluid Production Systems (FPS) - novel approach for versatility in production 1.2 Müller et al. Identification of reconfiguration demand and generation of alternative configurations for Cyber-Physical Production Systems 1.3 Trierweiler and Bauernhansl Operative Control of Production Equipment in Matrix Structured Assembly Systems 1.4 Schopper et al. A User-friendly Assembly Planning Tool for Assembly Sequence Optimization 1.5 Göppert et al. Agile hybrid assembly systems: bridging the gap between line and matrix configurations 1.6 Dürr et al. Development of an integrated datadriven process to handle uncertainties in multi-variant production and logistics: A survey 1.7 Kärcher and Bauernhansl Method for Data-driven Assembly Sequence Planning 1.8 Neb and Scholz A novel approach to generate assembly instructions automatically for CAD models 1.9 Klaiber et al. Highly integrative rear end concept of battery electric vehicles p. 20 p. 21 p. 22 p. 23 p. 24 p. 25 p. 26 p. 27 p

12 Overview of the Scientific Sessions Session 2: Data Management & Interoperability 2.1 Eheim et al. On automation along the automotive wire harness value chain 2.2 Till and Rudolph Digital Modeling of the Product lifecycle: essentials of 5 years of ZAFH research 2.3 Karkowski Generic and Scalable Modeling Technique for Automated Processes 2.4 Zhao and Cottyn The role of AutomationML within an industry 4.0 environment 2.5 Li et al. An ISA-95-based Middle Data Layer Solution to Support Data Standardization for System Integration in Factory Automation 2.6 Klöser et al. Deep Reinforcement Learning for IoT Interoperability 2.7 Komesker et al. Structured information processing as enabler of versatile, flexible manufacturing concepts 2.8 Ewert et al. A lightweight implementation of the Asset Administration Shell concept for practical use and easy adaptation 2.9 Juarez and Lipp Wireless industrial networks for realtime applications p. 32 p. 33 p. 34 p. 34 p. 35 p. 36 p. 37 p. 38 p

13 Session 3: Manufacturing Technologies Session 3: Manufacturing Technologies 3.1 Kaufmann et al. Selective assembly strategy for quality optimization in a laser welding process 3.2 Graf et al. A Universal Machine: Enabling Digital Manufacturing with Laser Technology 3.3 Walz and Werz A new concept for producing high strength aluminum line joints in car body assembly by a robot-guided friction stir welding gun 3.4 Nitsche et al. Experimental and theoretical study on depth of cure during UV post-curing of photopolymers used for additive manufacturing 3.5 Dittmann et al. Simulation supported manufacturing of profiled composite parts with the braiding technique 3.6 Esch et al. Integrated machining, sealing and quality inspection for CFRP components 3.7 Helber et al. Multi-robotic composite production of complex and large-scaled components for the automotive industry 3.8 Fial et al. Enhancing textile forming using textileapplied strain sensors and segmented blank holder systems 3.9 Liewald and Schenek Production of thin outer skin car body panels by using novel Short Cycle Stretch-forming (SCS) technology p. 42 p. 43 p. 44 p. 45 p. 46 p. 47 p. 48 p. 49 p

14 Overview of the Scientific Sessions Session 4: Logistic Concepts and Enabling Technologies 4.1 Ranke and Bauernhansl Evaluation of material supply strategies in matrix-structured assembly systems 4.2 Popp Implementation of a goods-to-man concept by means of automated guided vehicles and a flexible fleet management 4.3 Stillig Novel Autonomous Guided Vehicle System for the Use in Intra-Company Logistics 4.4 Strametz et al. Increased Agility by Using Autonomous AGVs in Reconfigurable Factories 4.5 Mayershofer and Fottner Towards Artifical Perception for Autonomous Mobile Robots in Logistics 4.6 Korte Concept of a safety-related sensor system for collaboration between human and automated guided vehicles 4.7 Hofmann Safety and operating concept for collaborative material flow systems 4.8 Otto et al. Merging compliant safe collaborative and high-accuracy operations in industrial robots: a model predictive controller for adaptive behavior 4.9 Hesslein et al. Industrial Indoor Localization: Improvement of logistics processes using location based services p. 52 p. 53 p. 54 p. 54 p. 55 p. 56 p. 57 p. 58 p

15 Session 5: Sustainability & Energy Efficiency in Production Session 5: Sustainability & Energy Efficiency in Production 5.1 Kaymakci and Schneider FlexPress - An implementation of energy flexibility at shop-floor level for compressed-air applications 5.2 Al Assadi et al. Automated environmental assessment via an asset administration shell 5.3 Leberle and Weigelt Economic feasibility of highly adaptable production system 5.4 Block et al. Developing Technology Strategies for Flexible and Changeable Automotive Products and Processes 5.5 Reisinger et al. A novel Automated Hardware Upgrade Service for Manufacturing Systems 5.6 Anzolin and Andreoni 5.7 Stahl and Mesa Cano Robotising, but how? Organisational innovation and heterogeneity in the use of digital production technologies. Evidence from Japanese and German companies in the automotive sector. New approaches for business model innovation in manufacturing equipment companies p. 62 p. 62 p. 63 p. 64 p. 65 p. 66 p

16 Overview of the Scientific Sessions Session 6: Body in White & Painting 6.1 Todtermuschke et al. The fully flexible body shop - a holistic approach for the vehicle production of tomorrow 6.2 Till et al. Automated generation of clamping concepts and assembly cells for car body parts for the digitalization of automobile production 6.3 Birkert and Nowack p. 70 p. 71 Adjustable Hemming Die p Facciotto et al. Modelling Defects of Unhardened Adhesives Resulting from Handling and Warpage: Viscous Fingering 6.5 Güttler et al. A self-programming painting cell Self- Paint : Simulation-based path generation with automized quality control for painting in small lot sizes 6.6 Preiß et al. Less chemicals and more power: Pulsed Electric Field (PEF) treatment for reduction of microorganisms. A biocidefree bath maintenance method in pretreatment of dip coating plants. 6.7 Brag and Rochowicz Safety in electromobility Technical cleanliness between the poles of design requirements and efficient production p. 73 p. 74 p. 75 p

17 Session 7: Smart Systems & Services in Manufacturing Session 7: Smart Systems & Services in Manufacturing 7.1 Sarivan et al. Deep Learning Enabled Real Time In Site Quality Inspection Based On Gesture Classification and Force Estimation 7.2 Taha et al. Robotic Arm s Anomalies and Degradation Monitoring and detection by Using Machine Learning 7.3 Moosmann et al. Using Deep Neural Networks to Separate Entangled Workpieces in Random Bin Picking 7.4 Khalid et al. Automatic gripping point generation for vacuum grippers for Random Bin Picking 7.5 Abicht et al. Operator emulation through robot cells enables a highly flexible automation of secondary activities on machine tools 7.6 Kim et al. Flat knitted sensory work glove for process monitoring and quality assurance 7.7 Aboelhassan et al. A Framework for Digital Twin Deployment in Production Systems 7.8 Herlyn The smart factory and the unique digital order twin 7.9 Tasci et al. Predictable and real-time message-based communication in the context of control technology p. 78 p. 78 p. 79 p. 80 p. 81 p. 82 p. 83 p. 83 p

18

19 Session 1: Next Generation Automotive Production This session focuses on new concepts for automotive production systems encountering the demands of volatile markets and further increasing product variants. This session also considers new approaches for optimized assembly planning and production control as well as the introduction of new vehicle concepts. 19

20 Scientific Sessions Session Fluid Production Systems (FPS) - novel approach for versatility in production Christian Fries ab, Michael Trierweiler ab, Daniel Ranke ab, Anwar Al Assadi ac, Hans-Hermann Wiendahl ab, Petra Foith-Förster a, Manuel Fechter a, Thomas Bauernhansl ab a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany c ARENA2036 Research Campus Volatile market demands, further regionalization of markets, ever-shortening product and innovation cycles as well as an ongoing personalization of products increase the need for adaptable production systems. More than a hundred years after the start of mass production, alternative production systems are required to go beyond the current state of the art concerning adaptability, flexibility and re-configurability to market changes and demands. This paper shall outline the method to design and appropriately use Fluid Production Systems (FPS) in manufacturing. The basic idea behind FPS lies within their possibility to dynamically adapt and change all logistic and production processes based on the comprehensive application of cyber-physical production systems (CPPS) and thus enabling ongoing change in setup, configuration and product scope. The processes are therefore continuously assessed, benchmarked and re-configured matching the functional capabilities of production and logistic resources to the actual requirements originating from products and external influencing factors. Within this paper, the Fluid Production System is described in detail. For differentiation from conventional production systems, the FPS is compared to actual production systems such as the Matrix Manufacturing System (MMS), Dedicated Manufacturing Lines (DML) and Flexible Manufacturing Systems (FMS). Core hypotheses of the structural setup and corresponding process specifications in FPS are established and qualitative decision criteria to define suitable application areas for FPS are defined. The paper closes with an outlook into preliminary results from industrial implementation projects, best practices and lessons learned. 20

21 Session 1: Next Generation Automotive Production 1.2 Identification of reconfiguration demand and generation of alternative configurations for Cyber-Physical Production Systems Timo Müller a, Simon Walth a, Nasser Jazdi a, Michael Weyrich a a Institute of Industrial Automation and Software Engineering IAS, University of Stuttgart, Germany The frequency of changes in production requirements is continuously increasing due to shorter product life cycles. This leads to an increased reconfiguration demand during operation. The future of industrial automation will be dominated by Cyber-Physical Production Systems (CPPS), which offer many promising potentials, especially up-to-date models to perform reconfiguration management in a self-organized manner. However, the question arises how to utilize this potential for a self-organized reconfiguration management. Therefore, a basic concept for a self-organized reconfiguration management is presented, which covers a methodology containing the four steps: identification of reconfiguration demand, generation of alternative configurations, evaluation of configurations, and the selection of a new configuration. This contribution focuses on the first two steps: The identification of reconfiguration demand and the generation of alternative configurations. At first, the literature concerning these two steps is presented. Then the methodology and the information modeling which utilizes the PPR-concept by the means of formalized process description, are presented. To identify the reconfiguration demand a comparison between the target production and the actual configuration of the CPPS is conducted. In case, that the target production cannot be transacted by the current configuration, the generation of alternative configurations takes place. Within the generation of alternative configurations, firstly alternative configurations at machine level are generated by the Cyber-Physical Production Modules (CPPMs) based on the given production requirements. Then different alternative production sequences are determined by mapping the CPPMs to production steps based on the resulting set of possible CPPM configurations and are subsequently located within the layout of the CPPS. This forms the basis for the simulated optimization and selection of configurations, which is presented within future work. To evaluate the concept, an agent-based implementation is given, which utilizes an OPC-UA controlled modular production system with a matrix layout, simulated in Unity as a substitute CPPS. In the end a conclusion is given. Session 1 21

22 Scientific Sessions Session Operative Control of Production Equipment in Matrix Structured Assembly Systems Michael Trierweiler a, Thomas Bauernhansl a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany Since the introduction of the assembly line in production around 100 years ago, the principal of mass and series production has not changed much. However, in the last decades more individualized products lead to higher product variants, which challenge ordinary rigid linked assembly lines. To provide a higher adaptability on changing product variants and volumes, in manufacturing as in assembly, the concept of matrix structured production is developed. Here, the equipment of the production system is composed of various process modules, which provide the needed functions. Depending on the needed functions, the work pieces literally search by and by their way through the production. The process modules themselves consist of one or more stations, which provide the process functionalities. Assuming that these stations can be distributed to the various process modules in a short time, this production structure offers a high changeability during operation. Furthermore, the hypothesis can be stated, that a matrix production system for each production plan can be configured in an optimal way, depending on the set production targets, whereas the benefit of the reconfiguration exceeds the needed effort. Through the high degrees of freedom a matrix production system offers, finding this optimal configuration of the equipment can be seen as a complicated task. Since so far no method exists, this paper gives an overview of the task and sketches an approach of how to find and realize an optimal configuration of production equipment during operation of the production system. Finally, the needed research to realize that approach is outlined. Here, the restrictions and boundary conditions are assessed. Furthermore, it is discussed, how the core element of the method finding the optimal configuration can be realized. Finally, it is examined where to implement the method in the production organization. 22

23 Session 1: Next Generation Automotive Production 1.4 A User-friendly Assembly Planning Tool for Assembly Sequence Optimization Dominik Schopper a, Claudia Tonhäuser a, Stephan Rudolph a a Institute of Aircraft Design, University of Stuttgart, Germany In order to maintain competitiveness, companies are continuously exploring ways to reduce manufacturing costs and optimize production quality. The systematic rationalization in the manufacturing sector has shifted the focus of cost generation to assembly. Today, companies face the challenge of reducing assembly costs, which account for 50-70% of total manufacturing costs. An automation level as it applies in the manufacturing sector is sophisticated, since assembling geometrically complex components is difficult. Analyses confirm that in many cases considerable reserves are not fully exploited yet. The presented work takes up this problem and offers an approach to exploit the full potential of the assembly process. Digitalization offers new opportunities to significantly improve the quality of planning, adaptation and optimization of assembly processes through direct human machine interfacing. The suggested approach allows for the replanning of the assembly process and its supplementation with alternative assembly paths. Since multiple valid assembly sequences usually exist for one and the same product, differing sequences are optimal depending on the optimization goal (e.g. time or costs). In this context, an automated assembly path analysis should enable the identification of a time-optimal sequence. The implementation is realized using graph-based design languages as modeling framework. This allows an easy integration of the assembly planning process into the digital design process. The possibility of generic modeling in the design language enables a uniform and unique representation of all assembly sequences. During the modeling process the level of detail can be freely defined by the user. Afterwards the design language is translated into a design graph by a compiler. This graph contains all user-defined assembly priority plans and serves as a data basis for optimization. Due to the graphical representation, established graph algorithms can be executed to find an optimum. Eventually a graphical user interface was implemented to facilitate the input of the possible assembly processes. In combination with the design language a user-friendly assembly planning tool is created. Session 1 23

24 Scientific Sessions Session Agile hybrid assembly systems: bridging the gap between line and matrix configurations Amon Göppert a, Esben Schukat a, Peter Burggräf ab, Robert H. Schmitt a a Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany b Chair of International Production Engineering and Management (IPEM), University of Siegen, Germany The ongoing transition towards electromobility demands for increased reactivity and reconfigurability in automotive assembly. However, the traditional line assembly, which is characterized by rigid cycle times and linear product flow, has already been driven to its flexibility limits. Drivers are the increase of product changes as well as of variants and derivatives within assembly lines. To further increase reactivity and reconfigurability, matrix structured assembly configurations are a possible solution. Several studies highlight the theoretical advantages, but it has not been applied and validated in industrial use-cases, due to the high transformational gap between line and matrix configurations. In contrast, segment-wise line-less structures show a high potential for this. A use-case oriented approach improves reactivity and reconfigurability by implementing an agile hybrid assembly system that combines the advantages of line and matrix structured assembly system. Three fields of action are presented: The first deals with reconfigurable infrastructures, which comprises of short-term dispatching intralogistics and a flexible layout, facilitated by AGV transport routes and reconfigurable self-adaptive workstations. The second field of action consists of flexible planning and control software modules. Within the planning phase, an automated scenario analysis is performed for optimization by applying simulations. During the production phase, the simulated model is re-used for the operation of a dynamical multi-agent manufacturing execution system with online scheduling algorithms. The third field of action compromises a system model that is an underlying fully integrated digital twin. Control interfaces integrate the infrastructure into the manufacturing execution system to enable rapid system changes. The presented hybrid system contributes to the design of future assembly systems by showing which aspects of line and matrix configurations can be combined to have a beneficial impact on a broad spectrum of production scenarios. By considering all relevant fields of action in a holistic way and by analyzing a hybrid configuration, the arising challenges for producing companies are addressed in a practical and functional manner. 24

25 Session 1: Next Generation Automotive Production 1.6 Development of an integrated data-driven process to handle uncertainties in multi-variant production and logistics: A survey Simon Dürr ab, Matthias Kauffmann b, Raphael Lamprecht c, Jörg Winter b, Heinz Alexy b, Marco Huber cd a Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany b Dr. Ing. h.c. F. Porsche AG, Stuttgart, Germany c Center for Cyber Cognitive Intelligence CCI, Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany d Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany Session 1 A key differentiator in customer satisfaction in the automotive industry is offering the choice of high-dimensional possibilities to customize an individual vehicle. In figures more than one billion variants in the luxury segment. Innovative data-driven processes are necessary for the planning and handling of vehicles in production and distribution in order to guarantee indispensable factors such as stability, flexibility and transparency across the entire supply chain and to deliver the right vehicle to the right place at the promised time. Highly complex business environments, multi-variant products, trends with effects on distribution networks and future mobility concepts confront manufacturers with new challenges. This paper provides a survey of currently used methods and technologies to handle the previously mentioned challenges in the area of the customer order management of an automotive manufacturer. A specific field of research is the concept of planned orders derived from early anticipated customer requirements and its utilization throughout the entire planning and order management process. In addition to the higher-level and holistic approaches for achieving integrated planning of sales and production programs and the resulting material requirements, artificial intelligence methods are investigated with regard to the concept of the planned orders. For this purpose, various already existing approaches to anticipate planned orders, to simulate scenarios as well as algorithms to match real customer orders to planned orders are examined. In conclusion, this paper provides a survey of state of the art methods regarding artificial intelligence linked to current research on agile production systems. In this context the possibility to prepare an automotive manufacturer for the advancing digitalization and globalization is evaluated in order to establish stable data-driven processes to get a manufacturer ready for the coming years despite existing uncertainty. 25

26 Scientific Sessions 1.7 Method for Data-driven Assembly Sequence Planning Susann Kärcher a, Thomas Bauernhansl ab a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany Session 1 In many manual assembly systems there is great potential for optimization, especially when products in small quantities, high variants or with high complexity are produced. The more often the assembly is changed, the greater the potential. The main reason is the still high effort required for assembly planning. Especially in today s challenging and volatile environment, classic assembly planning often reaches its limits. As a result, assembly systems are often not planned in sufficient detail. The consequence is lack of transparency: Workers in assembly do not get clear work instructions and planners do not get feedback from assembly. There are approaches to reduce the effort required for assembly planning meeting the challenge from two sides: On the one hand, there are approaches to further integrate assembly planning with previous processes, such as product development. On the other hand, there are approaches that optimize the processes from an assembly perspective. This paper focuses on a method to optimize assembly sequence planning based on actual data. Data is collected, for example, via sensors in the assembly area. Afterwards different runs of the assembly process are analyzed. Then, an algorithm derives the best practice to assemble the product. Best practice describes the assembly process that leads to the fastest assembly. The method fits into a methodology to transfer benchmarking to manual assembly and can be used for an one-time optimization project as well as for continuous optimization. The results generated in the algorithm are then made available to workers and planners. 26

27 Session 1: Next Generation Automotive Production 1.8 A novel approach to generate assembly instructions automatically for CAD models Alexander Neb a, Johannes Scholz a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany For the distribution of consumer and industrial goods, every company is obliged to provide assembly instructions. For the consumer goods market, for example, the German Civil Code defines that defective assembly instructions must be declared as a material defect. However, the creation of comprehensible and defect-free assembly instructions is still a very timeconsuming manual process, which must be determined in an extremely time-consuming procedure. Nonetheless, assembly instructions are more than just obligatory documents. They are also required in places where they are not prescribed. For example, assembly instructions are needed in production to pass on assembly knowledge to the assembly operators. Here, it often turns out that this knowledge is either not available or can only be used to a limited extent. The two key elements of an assembly instruction are the assembly sequence and the visual illustrations. Currently, the assembly sequence is determined manually by the designers based on their personal experience, whereas illustrations are generated with costly software tools which are not even able to check the feasibility of the planned instruction. This work presents a novel approach to generate assembly instructions directly and automatically from CAD models of the designers. For this purpose, the commercial CAD software SolidWorks was extended by a Macro Tool. All necessary data to generate an assembly instruction are extracted from the CAD model. The extracted data are assembly features, stability and geometric restrictions, subassemblies and assembly directions. Based on this data, the assembly operations are evaluated with a fitness function which includes the attributes like tool changing costs or distances of assembly paths. The whole assembly sequence optimization process was modeled as a Travelling Salesman Problem. After the ideal assembly sequence was found by the Macro Tool, this tool also generates matching visualizations of the assembly operations based on the CAD model. The approach was validated by three different models, an assembly benchmark, a single-cylinder engine and a gear box. Session 1 27

28 Scientific Sessions Session Highly integrative rear end concept of battery electric vehicles Dominik Klaiber a, Philipp Kellner a, Matthias Biegerl b, Gabriele Gorbach b, Thomas Götz c, Marco Schneider c a Porsche AG, Weissach, Germany c ElringKlinger AG, Dettingen/Erms, Germany e Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany The current challenge to meet climate targets primarily involves the reduction of CO2 emissions in all industrial sectors. This problem was already addressed previously by the HigHKo project of a mass-reduced rear end for a battery electric vehicle to achieve substantial weight reduction through functional integration of all components, such as the battery housing into the body structure. Existing vehicle structures have always been designed according to lightweight principles. Hence, additional weight savings require new conceptual approaches to reduce component weight via functional integration and multi-material design. In the framework of the project, functional mass analysis is applied to systematically describe where mass reduction and functional integration can meaningfully be implemented. This implementation leads to concepts of composite designs of different metallic and polymeric materials. Given the current lack of experience concerning multi-material composites, a procedure for a knowledge-based application of suitable production and particularly joining technologies is elaborated for the development process. Specifically, three main components are redesigned: battery system, chassis and bodywork. At the example of the battery system, the tightened requirements, the highly integrative concepts and their production-related implementation are demonstrated. The newly developed Delta-Wing demonstrator made of fiber-reinforced plastics contains various functional components that are placed on a supporting structural element as part of a battery module. This demonstrator comprises a crash-resistant power line between battery and body, leak tightness as well as integrated metallic current carrying and conducting elements. It also fulfills thermal management requirements. During the project, the production technology for this hybrid Delta-Wing component is developed and implemented. The manufacturing concept ensures economic profitability of multi-material design due to its serial production capability. The concept relies on a single-shot injection molding process so as to integrate both metallic components and components based 28

29 Session 1: Next Generation Automotive Production on organic sheets. Thus, a significant weight reduction of the overall system can successfully be achieved through innovative structural integration and the demonstration of manufacturing feasibility. Session 1 29

30 Session 1

31 Session 2: Data Management & Interoperability This session addresses product management for connected industries. It combines technologies from the product and production domain, new concepts for wireless communication as well as semantic technologies for data interoperability. The session ends with the introduction and outlook into the all new assembly administration shell concept implemented at ARENA

32 Scientific Sessions 2.1 On automation along the automotive wire harness value chain Marc Eheim a, Dennis Kaiser a, Roland Weil a a IILS mbh, Trochtelfingen, Germany Session 2 Today, the wire harness represents the second most expensive part of an automobile and its complexity is expected to grow further. The associated wire harness value chain typically starts with the definition of the boundary conditions set by the original equipment manufacturer (OEM) with contractual specifications: A) predefined electrical circuit diagrams, B) the design space definition and C) dedicated component selections. It ends typically with the delivery of the designed and manufactured wire harness by the supplier to the OEM using just in-time and just in-sequence (JIT/JIS) logistics. Due to the high complexity and intensive coupling with all other complex parts in an automobile, such as control systems, navigation and infotainment, only the design, manufacturing planning and organisational tasks have remained in Europe, often in close proximity to the OEM. Due to the price pressure in global competition, the simple(r) manual wire harness assembly work has often been relocated into low wage countries, potentially thousands of miles away, turning the JIT/JIS delivery logistics into a nightmare. The current status quo of wire harness design and manufacturing is a mainly manual process chain of A) manual wire harness architecture selection, B) manual virtual 3D wire harness generation, typically in a so-called cable workbench module in a CAD-system. Downstream, the manual wire harness manufacturing process steps lead to a full-scale 2D formboard master plan for the manual wire harness assembly in a potentially far away country. Depending on the size and complexity of a wire harness, the whole development cycle may take up to 2 years (e.g. A380 wire harness). Using the results of the European ITEA3-Project IDEALISM, it will be shown how the complete automation of virtual 3D wire harness generation can be achieved using graph-based design languages. Furthermore, an outlook on the upcoming manufacturing automation of wire harnesses in a digital factory twin will be given. 32

33 Session 2: Data Management & Interoperability 2.2 Digital Modeling of the Product life-cycle: essentials of 5 years of ZAFH research Markus Till a, Stephan Rudolph b a Ravensburg-Weingarten University, Ravensburg-Weingarten, Germany b Institute of Aircraft Design, University of Stuttgart, Germany Graph-based design languages in UML (Unified Modeling Language) are a new approach to the digital modeling of product designs. In design languages, the individual concepts (i.e. the vocabulary ) represent reusable and freely (re-)combinable language building blocks. The assembly knowledge about the product (i.e. the rules ) are executed as language operations on the vocabulary. Graph-based means that the vocabulary are represented as nodes in a graph and serve as placeholders (i.e. abstract models) for real objects, processes or states. The object-oriented data model of the UML used for the representation of graph-based design languages originates from software engineering. It allows to represent the entire product knowledge along the product life cycle, i.e. to represent product requirements, design parameters and product functions during the development and the manufacturing and assembly of the product. The UML is internationally standardized and the product representation in UML may be further processed on an abstract level by means of machine-executable model transformations (i.e. the rules ). Finally, the holistic data model in UML is transformed into the domainspecific language representations (DSLs) of the analysis programs (MBS, FEM, CFD,...). This achieves a clear separation between the abstract knowledge representation in the form of graph-based design languages in UML and the dedicated domain-specific product representations in diverse programs and data formats of various software vendors. From the results of the 5-year ZAFH research project Digital Product Lifecycle (DiP), see for details, the design language development in UML for the entire product lifecycle is illustrated using a car front hood as an example. Besides the design and the functional verification, the production planning, factory layout and assembly sequence are automatically generated and simulated. The level of detail achievable in the digital factory simulation extends to the virtual commissioning. The ZAFH research project DiP thus represents an important further evolutionary step towards the transdisciplinary modelling of engineering design and manufacturing knowledge along the product life cycle. Session 2 33

34 Scientific Sessions 2.3 Generic and Scalable Modeling Technique for Automated Processes Martin Karkowski a a Zentrum für Mechatronik und Automatisierungstechnik ggmbh, ZEMA, Saarbrücken, Germany Session 2 Modularity, adaptability and integration of new technologies like Human Robot Cooperation (HRC) helps in facing the major challenges posed by the increased product variants with shortened life cycles and fluctuating market conditions of the automotive industry. However, utilizing them requires strong software support and complicates the already demanding planning and implementation of an assembly system. The strong dependency on software creates a new void in the planning and implementation processes. Usually the programmer, not the process owner, fills this void based on his knowledge. This results in frequent and resource intensive adaptations during commissioning due to implicit knowledge and requirements during the development process. This paper presents a lean approach for implementing an adaptable assembly system. Our approach combines an abstract process description, a virtual model of assembly system and a standardized control system which enables the realization of an assembly system. Our modelling technique helps a process owner to develop robust assembly systems. Also, it enables the design of a process and supports in obtaining the corresponding boilerplate code needed to execute the process on a standard hardware utilized by the industry. This is demonstrated and tested by means of a HRC underbody assembly process in vehicle assembly under realistic conditions in a demonstrator factory. 2.4 The role of AutomationML within an industry 4.0 environment Jiaqi Zhao ab, Johannes Cottyn ab a Department of Industrial Systems Engineering and Product Design, Ghent University, Belgium b Industrial Systems Engineering (ISyE), Flanders Make, Belgium AutomationML has been regarded as an open neutral data exchange format for the digital twin of automation systems since it was initiated in As time passed by, AutomationML has been used in many different areas in all kinds of application aspects. However, there is no comprehensive academic review on the research and application progress of AutomationML 34

35 Session 2: Data Management & Interoperability since the initiation of AutomationML concept. According to the study and analysis of AutomationML related research papers, this paper gives a detailed classification and analysis of the current research status of AutomationML. Since AutomationML came to public in 2008, nearly 200 AutomationML related papers have been published by different authors, at different affiliations and in different countries. This paper will not only make a conclusion of the publish amount ranking of relevant countries, affiliations and authors, but also give an overview of the popularity ranking of relevant academic conferences and journals. Besides, the research progress of all the AutomationML based research aspects is elaborated in this paper. For example, some of the papers are related to AutomationML based modeling, which includes automation system modeling, control system modeling, communication system modeling, product modeling, process modeling, resource modeling, simulation modeling, etc. Some of the papers are related to data exchange between software in the same area, such as data exchange between different 3D modeling software, between different logical programming software, between different simulation software, etc. Some of the papers are about the data exchange between AutomationML and other formats, the formats are like OPC UA, Asset Administration Shell, ISA 95, SysML, etc. According to the analysis results of AutomationML relevant papers, conclusion and outlook of the research and application on AutomationML are illustrated in the end. Session An ISA-95-based Middle Data Layer Solution to Support Data Standardization for System Integration in Factory Automation Chen Li a, Soujanya Mantravadi a, Casper Schou a, Hjalte Nielsen a, Ole Madsen a, Charles Møller a a Department of Materials and Production, Aalborg University, Denmark In order to achieve fast production and seize market share, manufacturers need to integrate business and manufacturing processes quickly and efficiently. One of the major challenges is how to smoothly reconstruct, aggregate and standardize data from the various systems (e.g, ERP system, MES, IoT platform) without interference with the existing business or manufacturing processes. This paper presents a middle data layer that is designed and implemented based on the ANSI/ISA-95 industrial standard. The proposed middle data layer helps to extract key information of manufacturing operations and control systems and business systems based on the mentioned standard, and standardize and formalize the data structure. We expand the above idea into four directions. First, we give a general 35

36 Scientific Sessions Session 2 view of a role-based equipment hierarchy cross different levels, i.e., Business, Manufacturing, Control, and the actual process. The purpose is to have an overview of what kind of activities should be considered for building a middle data layer from different levels. Second, we analyze the automation pyramid and try to restructure the traditional hierarchy levels by introducing the ISA-95 middle layer. Third, we identify the key objects and activities among those levels based on ISA-95 standards. By categorizing the data source, i.e., transaction data and master data, and data flows, we design the data architectures and explain how to formalize and standardize the master data and operation data. A case study is designed based on the integration of Odoo ERP, AAU MES and IIoT platform (i.e., Thingworx platform) by using the proposed ISA-95 middle data layer. The results show the middle data layer enhances the interoperability of manufacturing systems and create a universal standardized data structures for systems integration of factory automation. 2.6 Deep Reinforcement Learning for IoT Interoperability Sebastian Klöser ac, Sebastian Kotstein b, Timo Zerrer a, Christian Decker b a DXC Technology, Böblingen, Germany b Reutlingen University, Böblingen, Germany c HAVEN e.v., Hamburg, Germany Interoperability is an important topic in the field of Internet of Things (IoT), since it is a critical success factor for realizing novel IoT applications involving connected sensory devices, actors and other components. The term interoperability refers to the ability of two or more components to communicate and interact with each other to achieve a common goal. As the field of IoT is coined by a multitude of different communication protocols, data formats, and standards, an IoT setup often involves many different components that are not automatically interoperable to each other. In order to integrate these heterogeneous components into a uniform IoT environment, protocols and data formats must be adapted manually, which leads to a time-consuming task with a high manual effort. Considering that large IoT setups may consist of hundreds or even thousands of different components, a manual adaptation of different protocols and data formats is often not practical. Instead, we want to automate this integration process by learning and adapting the communication interfaces of components with Deep Reinforcement Learning (DRL). DRL is an actively investigated field of Machine Learning, which allows to design systems that autonomously develop complex control strategies based on simple reward signals. Recent 36

37 Session 2: Data Management & Interoperability successful applications of DRL include learning computer games, strategy games, robot control and autonomous driving. One very promising research domain is focusing on DRL systems with unstructured information as observations like in text-based games. In a collaboration between the Herman Hollerith Zentrum and DXC Technology, we investigate the application of DRL to achieve IoT interoperability. In this paper, we present the current stage of our research program. We present our methodological approach to frame IoT interoperability as a Reinforcement Learning problem with text-based observation spaces and use an early prototype to demonstrate the ability to learn and adapt a RESTful interface based on a predefined task. 2.7 Structured information processing as enabler of versatile, flexible manufacturing concepts Simon Komesker af, Wolfgang Kern bg, Achim Wagner c, Martin Ruskowski cdf, Thomas Bauernhansl eg a Volkswagen AG, Wolfsburg, Germany b AUDI AG, Ingolstadt, Germany c German Research Center for Artificial Intelligence, DFKI, Kaiserslautern, Germany d Technologie-Initiative Smart Factory KL e.v., Kaiserslautern, Germany e Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany f TU Kaiserlautern, Germany g GSaME, University of Stuttgart, Germany Session 2 Automotive production systems face the challenge to produce models and brands with different drive concepts and individually configured equipment variants in a highly efficient way. Searching potentials to increase productivity, the continuously optimized production concept of the assembly line is being questioned. Efficient alternatives to the rigidly linked material flow can only be successfully implemented, if the previously rigid information and control processes are designed as structured dynamical control loops. Studies on modular assembly systems in automotive industry have demonstrated potential for productivity gains through the implementation of an alternative, value-add-oriented process organization. A corresponding design for other areas, like the body shop, has already been indicated, but has not yet been planned for an entire factory. The rigid concatenation of mechanical production processes is the limiting factor; first, for an efficient implementation of product individualization and second, for a highly available robust production, which could optimize the overall factory production 37

38 Scientific Sessions Session 2 flow. Rising degrees of freedom in material flow control associated with more flexible production flow increases the complexity of the overall production system. Decision support for humans by planning systems with integrated control logic is thus a decisive factor for mastering complexity. At the same time, it creates the basis for implementing the vision of an autonomous and self-regulating factory. In order for this development to reach the next level of maturity, technological innovation must be made feasible on the factory floor. The overall performance of individually operating subsystems within complex IT system architectures is not sufficient. Only the search for cross-system optima will lead to acceptable overall system performance. This requires a cross-system information and communication model that can perform holistic information-based control on factory level. A structured AI-based Jidoka is proposed, an application of nested, intelligent control loops which support humans in experience-based decision making of dynamical production planning problems and derive reconfiguration measures. 2.8 A lightweight implementation of the Asset Administration Shell concept for practical use and easy adaptation Daniel Ewert a, Thomas Jung a, Thomas Stiedl a a Robert Bosch GmbH, Renningen, Germany The ARENA2036 is a joint research campus incorporating production assets from different industrial and academic partners. To allow the implementation of cross-partner value streams and work flows, a common middleware for online date exchange and asset operation is mandatory. We implemented a generic and lightweight middleware which follows the concept of Asset Administration Shells as specified by the platform i4.0. However, to allow for easy adaption and setup by a diverse range of partner we simplified modelling requirements and the complexity of the actual data exchange. The result is a specification for the self-description of an asset s capabilities in form of submodels and a convention on how to map this self-description onto MQTT. Additionally we integrated means for online discovery and state monitoring of all connected assets.the paper details the developed specification and conventions, and presents examples for successfully operating use cases at the ARENA

39 Session 2: Data Management & Interoperability 2.9 Wireless industrial networks for real-time applications Jorge Juarez a, Stefan Lipp a a Fraunhofer Institute for Integrated Circuits IIS, Erlangen, Germany One of the biggest challenges currently facing the industry is to make logistics and production systems more flexible. Technological advances are enabling a variety of new application scenarios, such as safe and efficient human-robot collaboration. In order to adapt rigid, outdated factory concepts to the requirements of the future smart factory, retrofit measures on existing machines and plants are necessary. An important building block for the modernization of factories is the networking of all automation components. This will enable the constant exchange of information between the participants, also in view of the new increased requirements. Wireless communication technologies play a major role in expanding the mobility and agility of sensors and actuators. This is because, they can be operated without the need for a fixed connection between the radio base and the radio node, allowing operation in harsh factory environments. In particular, wireless technologies are needed that are reliable and support deterministic cycle times in the range 1 ms. This paper presents an overview of the state of the art in real-time radio technologies. The focus for this lies on current developments in the standard developing organizations 3GPP (RAN 1 Working Item URLLC), ETSI (DECT Working Group URLLC) and IEEE (801.11be Extremly High Throughput). At the same time, will be the novel real-time radio technology UWIN presented, at which Fraunhofer IIS is currently working among others in the research projects IoT-COMMs and IC4F. UWIN can be used as a wireless extension or as an equivalent replacement for wired fieldbuses. Analogous to the topology of a fieldbus system, the radio base serves as a gateway to the wired infrastructure or for control. In addition, the time synchronization of up to one hundred mobile radio nodes is also controlled with guaranteed, extremely short cycle times. The radio system can adapt to any frequency band and focuses on packet transmission of telegram sizes 35 bytes in license-free bands. Session 2 39

40 Session 2

41 Manufacturing Technolo- Session 3: gies This session focuses on manufacturing technologies, such as joining technologies e.g. the appropriate use of laser in manufacturing, additive manufacturing and composite materials. 41

42 Scientific Sessions 3.1 Selective assembly strategy for quality optimization in a laser welding process Manuel Kaufmann a, Marco Huber ab, Ira Effenberger a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute of Industrial Manufacturing and Management, University of Stuttgart, Germany Session 3 To achieve the best possible product quality in assembly processes and to compensate existing geometrical variation of components, methods such as selective assembly are suitable. Since the components deviations propagate towards the final assembly, it is possible that tolerance specifications are exceeded and product functions might not be fulfilled. By a dedicated selection of components, assembly deviations can be minimized. In this paper, the selective assembly approach is studied on an industrial use case considering economic aspects by using an AI-based method. For an efficient solution, the number of parts from each component is kept small in order to minimize the necessary physical part storage. Moreover, scrap rates should be decreased by minimizing the number of remainder parts that are not assigned to an assembly partner. The selective assembly approach is studied for a laser welding process of two injection-molded plastic parts, a cover attached to a housing. Each part has individual geometrical deviations caused by the production process. Both the joining process and the assembly functionality are affected by the components deviations. Due to aligning the laser beam to a nominal welding path, the melting zone can be displaced and might cause a faulty seam. Consequently, this causes decreased mechanical properties like tensile strength of the joining, which impairs corresponding product functions. Here a new approach called virtual assembly is used in order to simulate the physical assembly, considering the holistic geometrical information of the parts. A set of 24 housings and 24 covers is measured using computed tomography. By performing the virtual assembly, the histogram of deviations in the range of the welding zone is derived. A specific material surplus in the welding zone is required, that forms the welding seam. Considering the histogram of all negative deviations, a potential physical penetration of housing and cover is revealed. Then optimal combinations are determined using a global optimization approach with genetic algorithms. 42

43 Session 3: Manufacturing Technologies 3.2 A Universal Machine: Enabling Digital Manufacturing with Laser Technology Thomas Graf ab, Volkher Onuseit ab, Max Hoßfeld ab a The Institut für Strahlwerkzeuge (IFSW), University of Stuttgart, Germany b Graduate School of advanced Manufacturing Engineering (GSaME), University of Stuttgart, Germany c InnovationCampus Future Mobility, University of Stuttgart, Germany The laser is the only tool that can address all six main manufacturing groups of the German standard DIN 8580 simply by applying different processing parameters. Given the present state of technology, however, different machine concepts are still being used for the respective applications. To enable digital manufacturing in its full consistency, novel, fully reconfigurable machines need to be developed. We therefore outline the further developments that are required to combine all presently known laser-based manufacturing processes on one and the same machine. As laser devices are already very mature and the knowledge about the fundamentals of laser materials processing is also very advanced, research must now be intensified on system engineering. In detail, new approaches for a highly dynamic and at the same time highly precise beam deflection in a volume that is scalable up to the order of 10 m3, correspondingly suitable kinematics, the integration of artificial intelligence, and flexible approaches for the handling of process media and components are to be aimed for. The vision is an intelligent machine, which is fed with CAD data, semi-finished products, or sub-components and that is capable to autonomously produce the desired components with a 100% quality guarantee at a batch size of 1 first time right and at the costs of comparable mass-produced items. For this, it independently selects the best production strategy and automatically orders the required raw materials and processing media. Such a fully flexible and autonomous laser machine will not only boost the implementation of digital manufacturing on a broad scale but will also enable the relocalization of value creation and manufacturing back into high-wage countries such as Germany and by this potentially disrupt today s globalized value creating networks. Session 3 43

44 Scientific Sessions 3.3 A new concept for producing high strength aluminum line joints in car body assembly by a robot-guided friction stir welding gun Dominik Walz a, Martin Werz a a Materials Testing Institute MPA, University of Stuttgart, Germany Session 3 In order to reduce the weight of car bodies while maintaining or increasing passenger safety, materials with higher specific and buckling strength are increasingly being used. In this context, ultra-high-strength aluminum alloys are used in addition to press-hardened steels. A major challenge now is to combine the ultra-high-strength aluminum alloys with each other and, if necessary, with other metals without losing their outstanding strength properties. Since the 1990s, with the so-called friction stir welding process there is a pressure welding technology that allows the joining of high-strength aluminum alloys with virtually no loss of strength properties. In this process, a rotating tool is pressed into the joint gap of the joining partners and moved along the joint gap to produce the actual weld seam. In order to absorb and dissipate the high process forces, an anvil adapted to the component is required on the opposite side of the weld seam. A joining process for the body-in-white assembly of aluminum and hybrid car bodies should have the following specifications: Joining high-strength aluminium alloys without hot cracks High-strength joints Sufficient service life of the joining device Robot-supported execution No complex and expensive component-adapted anvil Accessibility similar to resistance spot welding/rsw guns Based on these requirements, a process concept for a new type of robotguided friction stir welding gun for the production of short, merging welding seams was developed at the MPA Stuttgart and a patent application was filed. It was possible to develop a first functional model of the welding gun and successfully test the underlying kinematics in initial trials. The concept differs from other known solutions of that kind that process forces in the gun are largely compensated. In addition, the concept allows curved weld seams, such as those found in the automotive industry, being realized as polygon courses in a robust manner and without component-specific anvils. 44

45 Session 3: Manufacturing Technologies 3.4 Experimental and theoretical study on depth of cure during UV post-curing of photopolymers used for additive manufacturing Jan Nitsche a, Tristan Schlotthauer b, Florian Hermann a, Peter Middendorf b a Mercedes-Benz AG, Böblingen, Germany b IFB, Institute of Aircraft Design, University of Stuttgart, Germany Additive manufacturing offers great potentials for the manufacturing of small series or personalized parts in the automotive industry. Technologies like Stereolithography (SLA) or Digital Light Processing (DLP) are using layer-by-layer UV-curing of photopolymers to form three-dimensional objects. Especially for interior parts, there is a high demand regarding the surface quality combined with large production rates, which can be achieved by using SLA technologies. For photopolymers a high degree of cure is demanded to obtain a material with long-term stable physical and chemical properties. During processing in a stereolithography apparatus, a degree of cure between 70 and 90% is achieved. A subsequent UV post-curing enhances further polymerization and significantly increases the degree of cure. This results in higher crosslinked polymers with improved mechanical properties regarding strength and stiffness. This work concerns the dimensional limitations during UV post-curing of parts made of urethane acrylates by the DLP process. For this, based on previous studies, the effect of different wall thicknesses on the achieved degree of cure is investigated and linked to the mechanical properties by tensile tests. To investigate the depth of cure, green-state specimens are irradiated one-dimensionally by UV-light of a wavelength between 365 and 405 nm. Subsequent hardness measurements according to Shore D are used to determine the corresponding depth profiles. The influence of photoinitiator concentration, irradiation dose and wavelength on depth of cure is analyzed. The studied parameters do not show significant influence on the maximum achieved hardness on the top surface of the specimen while the depth of cure varies in a wide range. For a non-pigmented material, the depth of cure is between 1 mm and 9 mm depending on the exposure conditions and photoinitiator concentration. To predict the achievable depth of cure of novel photopolymers analytical models for the transmission and curing reaction are combined and verified with UV-transmission measurements. Session 3 45

46 Scientific Sessions 3.5 Simulation supported manufacturing of profiled composite parts with the braiding technique Jörg Dittmann a, Mathieu Vinot b, Peter Middendorf a, Nathalie Toso b a Institute of Aircraft Design (IFB), University of Stuttgart, Germany b German Aerospace Center (DLR), Institue of Structures and Design, Stuttgart, Germany Session 3 Composite materials have brought new development and sizing possibilities for structural components in transportation systems. Their high specific material properties are enabling weight reduction while keeping unchanged or even increasing structural performances. On the downside, composite materials are generally related to high material and manufacturing costs, as well as increased characterization efforts. The development of the braiding technique has been responding this need of cost reduction in industrial applications. Through this technique, profiled structures can be manufactured in a highly automated and reproducible process which can be optimized depending on the loading scenarios. Moreover, the material architecture of the produced composites leads to higher energy absorption capability compared to their unidirectional or woven counterparts and is particularly adapted for structure under crash or impact loading. In this paper, we investigate the influence of manufacturing parameters on the textile architecture and on the mechanical properties of the composite. To this purpose, flat specimens of biaxially and triaxially braided composites are manufactured and tested under quasi-static tension and compression loading. In a second step, a three-layer generic profile structure with variable geometry is produced to illustrate the potential of the braiding technique. To reduce development time and avoid costly pre-production loops, a digital twin of the braiding process is created. Within this framework, braid s architectures are predicted with multiple finite-element simulations at the mesoscopic scale and validated with experimental measurements. Numerical predictions and experimental measurements both show a strong influence of the braiding angle (as a result of the braiding speed) and core diameter on the textile architecture and consequently on the material properties. This paper finally provides a numerical estimation of the experimental process window, in which optimal material properties can be achieved for the structure. The authors wish to acknowledge the funding provided by the Federal Ministry of Education and Research Germany in the Research campus ARENA2036 DigitPro & Digitaler Fingerabdruck. 46

47 Session 3: Manufacturing Technologies 3.6 Integrated machining, sealing and quality inspection for CFRP components Philipp Esch a, Andreas Gebhardt a, Oliver Tiedje a, Andreas Frommknecht a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany Manufacturing processes of CFRP components are often characterized by a high fraction of manual activities especially in terms of handling, cleaning and edge sealing. The innovative machining process introduced in this track comprises a fully integrated and automated workflow reducing unnecessary handling and transportation activities. The concept has been realized on a 5-axis machine tool, providing enough workspace for large structural workpieces and the developed technology units. The units themselves are defined by their modularity, scalability and independency of the guiding machine. Key aspect of the innovative concept are four purpose built and developed interchangeable technology units, which are driven by the base machinery. Thus the machine s working scope is being enhanced from machining to a fully integrated workflow including quality inspection, cleaning, sealing and curing. Alternatively the units can be applied on any guiding machine for instance robotic systems. The developed process is exemplarily laid out as follows: First, the workpiece is machined with conventional cutting tools. Second to the dust intensive process, the workpiece is raised off the clamping system and the cleaning unit cleans the edge and border area from dust and particles. With clean surfaces, the quality inspection unit examines the machining quality and decides for quality compliance, rejection or reworking. With fulfilled quality requirements, the workpiece is further treated and the rough machining surface is sealed with a viscous UV coating with an innovative overspray free application technology without contamination of machinery and without evaporating any solvents, so avoiding explosion protection measures. For curing the sealing, the final technology unit is changed into the machine spindle and driven around the workpiece in perpendicular orientation to the edge surface. Focused UV light emitted by this unit cures the sealing in shortest time. The four units can be individually configured and controlled. The modular approach allows for a selected operation of any technology unit and given task. The workpiece is completely machined, cleaned, inspected and sealed. Session 3 47

48 Scientific Sessions 3.7 Multi-robotic composite production of complex and large-scaled components for the automotive industry Florian Helber a, Stefan Carosella a, Peter Middendorf a a Institute of Aircraft Design, University of Stuttgart, Germany Session 3 Automated Composite Manufacturing via the Automated Fibre Placement (AFP) or Automated Tape Laying (ATL) are primarily used in the aerospace sector due to high acquisition cost and limited flexibility concerning applicable reinforcement materials. Especially for the automotive industry, these technologies are not of interest due to limited cycle times and the mentioned limitations in reinforcement materials. The Advanced Ply Placement (APP) however offers users the maximal degree of freedom concerning fabric utilization. A unique multi-robotic handling process allows the APP to process dry fibers as well as pre-impregnated fibers with a large variety of fiber areal weights and material types. With the APP approach, automated, wrinkle free placement of wide, unidirectional fabrics onto complex, double curved geometries is possible. This is guaranteed due to the utilization of coordinated robots during the layup process. Furthermore, the APP process offers the possibility to manufacture hybrid laminates without time-consuming changeover processes and the exchange of end effectors within the APP robotic cell enables enhanced applicability. E.g. end effectors mounted on quick change systems can rapidly be replaced to handle and join flexible structures via ultrasonic welding. The offline trajectory planning of the APP process is realized via Flexi- CAM, a CAE interface for geometry based path generation. Within Flexi- CAM databased parameter adaption and process simulation is carried out and the machine code is directly exported to the respective machine control system. The present paper will explain the working principles of the multi-robotic Advanced Ply Placement and distinguish between established automated manufacturing processes. Results on geometry based path generation via FlexiCAM and their applicability in the automotive industry will be discussed and the benefits of knowledge-based offline path planning will be highlighted. 48

49 Session 3: Manufacturing Technologies 3.8 Enhancing textile forming using textile-applied strain sensors and segmented blank holder systems Julian Fial a, Stefan Carosella a, Peter Middendorf a a Institute of Aircraft Design, University of Stuttgart, Germany Preforming is a crucial step in the production of modern continuous fibre reinforced composites and has a major influence on the mechanical performance of the component. During textile forming, also known as draping, a flat two-dimensional textile is transformed into the final threedimensional component geometry. The reinforcing fabric is deformed by specific mechanisms on yarn level, which leads to the final fibre architecture. One common way of implementing textile draping is the punch and die process. It is amongst others used for RTM and wet compression moulding processes and therefore addressed in this work. This paper describes the in-situ monitoring of specific deformation mechanisms during the draping process using the commonly known double dome benchmark geometry. These mechanisms are analysed and quantified by a novel kind of printed strain sensor. Such sensors are applied reversibly to the textile in order not to affect the fibre matrix adhesion of the later component. The merit of this quality assessment method is demonstrated in combination with segmented blank holder systems. This permits varying the textile retention forces locally, which leads to locally manipulated fibre angles and finally influences the mechanical performance of the target component. The authors would like to acknowledge the funding provided by the Ministry of Science, Research and Arts of the State of Baden-Württemberg in the scope of the research project Forschungsbrücke. Session Production of thin outer skin car body panels by using novel Short Cycle Stretch-forming (SCS) technology Mathias Liewald a, Adrian Schenek a a University of Stuttgart, Germany Sheet metal outer skin parts of automotive vehicles are mainly produced by deep drawing, as ben-eficial component properties such as resistance to stone and hail impact can be achieved. These beneficial properties do result from strain hardening mechanisms caused by the relatively high de-formation of sheet metal materials during the forming process. However, in the case of relatively flat components such as doors or roofs, the sheet metal material is rarely strain hardened during forming by deep drawing 49

50 Scientific Sessions Session 3 due to their low drawing depth. Considering this, a novel manufacturing process has been developed at the IFU of the University of Stuttgart, which combines stretch form-ing and deep drawing offering following advantages: Simple tool concept, which only consists of each one piece upper and lower tool without conventional blank holder Restrain of blank and control of the material flow exclusively by beadlike form elements Improved sheet metal part properties due to increased plastic strain levels being achieved Cost-saving and lightweight construction potential due to higher material strength The Short Cycle Stretch-forming (SCS) tool concept exclusively consists of two one piece upper and lower tool each having bead-like form elements surrounding the outline of sheet metal component edge. By closing upper and lower tool, blank at first is laterally pre-stretched by mentioned form elements and thus pre-strengthened to a certain extent. After stretch forming, the part is shaped mechanically by the punch and the die geometry of the tool. This combination of stretch forming and deep drawing finally results in a high resistance to hail and stone impact for flat components. In this contribution, the SCS process is presented and the feasibility of a cost-effective production of strength-optimized sheet metal parts using this process is demonstrated by means of low batch series components for special car bodies. 50

51 Session 4: Logistic Concepts and Enabling Technologies This session discusses logistics concepts for matrix structured production systems, also looking into AGV technologies as well as supply chain management in battery production. The session concludes with an outlook into safety considerations for collaboration between human and machine. 51

52 Scientific Sessions 4.1 Evaluation of material supply strategies in matrix-structured assembly systems Daniel Ranke ab, Thomas Bauernhansl ab a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute of Industrial Manufacturing and Management IFF, University of Stuttgart, Germany Session 4 Today s productions are driven by an increasing variance, uncertainty of variance-distribution as well as volume, and shorter innovation cycles. These challenges especially confront assembly systems, as they have a high share of the value creation and individualisation process. The matrix-structured assembly system aims to overcome these challenges. The new system consists of independent and flexibly linked process modules, which have no uniform cycle time and no fixed products order-sequence in the system. It s more agile. However, through this system new challenges arise. The changes in the assembly-structure have an impact e.g. on the logistic, the planning & control or the information flow. In research there are only a few investigations regarding the consequences to the logistic, especially to the material supply, which is directly linked to the assembly. Common and new innovative supply approaches are used, without knowing their suitability to the new system. The applicability of KANBAN, single-product supply or kitting-basket supply differs, but a systematic derivation of suitability in the new context is missing. The paper encounters the lack of research in the outlined field. Firstly, changes and characteristics through the new structure, which occur as challenges to the material supply, are investigated. These are e.g. the flexibility of order- and process-sequences. In a second step, material supply strategies are evaluate to the outlined characteristics. As a result, each material supply strategy s suitability is evaluated for usage in matrixstructured assembly systems. The paper concludes with a derivation of guidelines for the selection of a material supply strategy, depending on the demand structure and material flow characteristics of the system. In conclusion, the paper contrasts common and innovative strategies. Furthermore, it contributes a guidance in the strategies selection process. Thus, it adds new insights in designing efficient logistic systems for matrixstructured assembly systems. 52

53 Session 4: Logistic Concepts and Enabling Technologies 4.2 Implementation of a goods-to-man concept by means of automated guided vehicles and a flexible fleet management Julian Popp a a MHP Management- und IT-Beratung GmbH, Porsche, Ludwigsburg, Germany The goods-to-man concept is a well-established procedure for material disposition in the automotive industry and in manufacturing companies that are characterized by multi-variant production. The increasing customer orientation characterized by a high variety of variants, smaller batch sizes, a higher product complexity and shorter release cycles in-creasingly force companies to replace the predominant line side material provisioning by a flexible material transport. Such concepts must adapt the material flow dynamically and automatically in order to be able to react flexibly to changes in the production sequence or layout. Therefore the conceptual work an innovative goods-to-man solutions using automated guided vehicles (AGVs) from various manufacturers in combination with a specially devel-oped fleet manager took place. Material required for production is transported to the re-spective production line in the correct sequence using carriers that are picked up by the AGVs. Thereby the flexible control of the AGV-fleet is carried out using an optimizer. Within this software a wide range of transport options is pre-simulated to identify the optimal solution. Via universal software interfaces, the compatibility with vehicle control systems from various manufacturers is provided. For the control of the AGVs, customer and transport-related data is read in via interfaces to manufacturing execution- or logis-tics- /warehouse management software. In addition, Graphical User Interfaces serve to monitor and control the transport processes. Using this concept combined with the communication to existing ITsystems and sensors, production logistics can be optimized and a flexible material flow can be achieved. In addition to the reduction of pre-scheduled tugger trains and the manual goods identifi-cation process, throughput times are also reduced. Furthermore, this system is character-ized by a higher reliability, as mistakes due to direct delivery of the goods and the system-side process control are reduced. Session 4 53

54 Scientific Sessions 4.3 Novel Autonomous Guided Vehicle System for the Use in Intra-Company Logistics Javier Stillig a a Institute of Electrical Energy Conversion IEW, University of Stuttgart, Germany Session 4 If future production facilities will have to be reconfigured more frequently than today due to volatile market influences and technical changes, there is a need for more convertibility in all facilities involved in the production process. For example, Automated Guided Vehicle (AGV) transport systems are well known for a long time, but their flexibility and cost reduction potential are limited, so that even today many internal material transports are planned and executed manually. This is where the novel concept of an AGV system comes in, which, in combination with the Intelligent Floor (IF) an infrastructure platform for convertible production (CP) reduces or even completely removes the disadvantages of current systems. Compared to existing systems, the presented Box-AGV is a simply designed and lightweight logistics robot with omnidirectional wheels, which can carry boxes with a payload of up to 20 kg on the IF. For this purpose, all relevant control and navigation information is provided by the IF, whose central control enables the coordination of all Box-AGVs. Furthermore, the Box-AGV is dynamically charged along a route via a new wireless power transfer unit. This modular design concept allows a cost-efficient and highly flexible transport automation, especially in applications with medium to high material throughput. In order to increase the efficiency of internal logistics, the IF can be used to track material movements in production in real-time, optimize them using AI technology and report back to man and machine as an assistance function. 4.4 Increased Agility by Using Autonomous AGVs in Reconfigurable Factories Daniel Strametz a, Michael Reip b, Rudolf Pichler a, Martin Höffernig c, Michael Pichler a a Graz University of Technology, Austria b incubed IT GmbH, Hart bei Graz, Austria c Siemens AG Austria, Graz, Austria AGVs have come up to a quite familiar picture of nowadays manufacturing sites. They follow rigidly prescribed maps of the shopfloor and they are 54

55 Session 4: Logistic Concepts and Enabling Technologies undoubtedly important parts of best known hard automation concepts. Future-oriented concepts require an even more agile manufacturing design that is ready to get its resources quickly realigned and work with frequently adapted layouts. Accordingly this has to be mastered by the management and command structures of a dynamically working AGV fleet. The presented work deals with a manufacturing concept where its resources, especially its Mobile Working Stations (MWS), are all equipped with Real Time Location System (RTLS) gateways which permanently provide their dynamic positions at the shopfloor. The actual research develops an AGV control system that is able to process this dynamically changing location data for providing an always updated logistic situation for the AGVs. This enables the AGVs for an automatically triggered re-routing in real-time according to changed goal positions or even to hand-over products to a seemingly better positioned AGV colleague. The testing environment for this project will be the smartfactory@tugraz, a pilot factory for research in digital manufacturing with its existing 5G campus solution infrastructure. The expectations of this higher communication standard compared to WiFi lie in the achievement of higher performance, higher security and much lower latency times. As for building up a 5G campus solution is quite expensive, there will also be installed a cloud-based server solution that uses the public radio network for communication. Such an off-the-shelf solution shall lower the entry costs for flexible automation in SMEs dramatically. In all variants security issues are obtained with highest priority, that is why solutions as VPN applications and similar are foreseen. With this modern approaches and solutions agile manufacturing can be run at a very high level, this without missing safety and security and still at reasonable costs. Session Towards Artifical Perception for Autonomous Mobile Robots in Logistics Christopher Mayershofer a, Johannes Fottner a a Technical University of Munich TUM, Germany Autonomous mobile robots (AMRs) in logistics are a promising approach towards a fully automated material flow. In order to use their full potential however, they must be able to extract semantic information from logistics environments. Up until now, research has not been addressing a wholistic approach to artificial perception for AMRs within the application field of logistics. In order to cope with these challenges, we propose a framework for artificial perception in logistics that aims to close this gap in a sustainable, data-driven way and initiate the necessary paradigm shift for AMRs in 55

56 Scientific Sessions logistics. Our framework consists of three components: First, standards, concepts and requirement for an artifical perception system are defined. Second, an artifical perception system is proposed. Third, a benchmark suite is developed. The framework leverages advances in artificial intelligence and expands it to the logistics domain. Similar to other AMR research, we aim to build a common, open-source platform for data-driven research and development. 4.6 Concept of a safety-related sensor system for collaboration between human and automated guided vehicles David Korte a a Institute of Mechanical Handling and Logistics, University of Stuttgart, Germany Session 4 The automotive industry and other manufacturing sectors are currently undergoing major changes. The changed framework conditions, such as shorter product life cycles, the customer s desire for more individual products and thus smaller batch sizes have an impact on the production of a wide variety of products. Production systems must become more convertible, as it is subject to frequent redesign. This also has an impact on the use of automated guided vehicles (agvs), which no longer only use defined routes, but must also be able to adapt dynamically to their environment in the future. Since humans will continue to play an important role in these adaptable production systems in the future, safe coexistence and collaboration between humans and machines, especially agvs, must be ensured. In most cases, laser scanners are used to safeguard agvs, but they can only detect obstacles in their environment in one plane. Due to the non-existent ability of the sensors to differentiate between humans and objects, the agvs are not able to adapt their behavior to the environment. This is also noticeable in the transport performance and thus the throughput of the agvs. For example, a column can be passed at a higher speed, like a human standing on the edge of the roadway. This previously unachievable sensor function can be implemented with the aid of a safety-related sensor system for agvs. In this paper a conceptual sensor system shall be presented which is able to detect humans in its environment, determine their position and provide this information to the control system of the vehicle. The concept was validated with the help of a demonstrator, which will also be presented in this paper. 56

57 Session 4: Logistic Concepts and Enabling Technologies 4.7 Safety and operating concept for collaborative material flow systems Matthias Hofmann a a University of Stuttgart, Institute for Mechanical Handling and Logistics IFT, University of Stuttgart, Germany The automotive industry, including their whole parts and component manufacturers, are facing challenges in a dimension not yet known. The strong differentiation of the product portfolio in connection with specific production lines holds a high vulnerability to capacity fluctuations in certain lines due to volatile demand within a manufacturer s product spectrum. This was especially apparent after the onset of the financial crisis of From the present point of view, the production of automobiles with fundamentally varying technical specifications requires a flexible and scalable production which enables an efficient production of batch size one. The key elements of a new concept, developed at the IFT are collaborative intralogistics components. One such system called Mobile Supermarket specializes on the supply characteristics of frequently needed parts with high variety to a Mobile Assembly Island. The Mobile Supermarket system consists of a compact AGV which transports mobile shelf modules as well as a non-stationary picking unit for handling the loading and unloading of small load carriers (VDA-KLT) from mobile shelf modules. The picking unit consists of a semistationary mini storage and retrieval system (Mini-ASRS), which hands the employee the material needed in a direct man-machine collaboration. The Mini-ASRS was primarily designed to provide a non-stationary piece of equipment. In this case there is no possibility to use fixed guards or stationary optoelectronic sensors as protection system. Therefore, new protection concepts including interfaces for man-machine collaboration are needed when employees should be able to interact with AGV s and automatic machines in small space. In consequence, the communication, concerning a form of articulation and perception between human beings and autonomous machines, has to be enhanced to avoid emergency stop of the machines caused by misunderstandings. As a result, flexibility means in this context an intelligent connection and communication between several systems of the production equipment to establish some kind of sharedsafety architecture which has to be integrated in machinery and safety controllers of the plant. Session 4 57

58 Scientific Sessions 4.8 Merging compliant safe collaborative and high-accuracy operations in industrial robots: a model predictive controller for adaptive behavior Andreas Otto a, Shuxiao Hou a, Uwe Frieß a, Marcel Todtermuschke a, Mohamad Bdiwi a a Fraunhofer Institute of Machine Tools and Forming Technology IWU, Chemnitz, Germany Session 4 In the era of industry 4.0, the industrial robots should possess various capabilities and sometimes they should serve contradictory goals. In some applications, the robot should have high stiffness capabilities to perform complex tasks with high accuracy at the end-effector. On the other hand, a collaboration of the same industrial robot with humans in a sharedworkspace is desired, where additional safety functions and characteristics, such as compliant joints, are required to be fulfilled. In this work, we present an enhanced model predictive controller coupled with an online task-oriented path planner to satisfy diverse and sometimes contradictory demands on industrial robots. The task-oriented path planner generates the reference path of the robot based on an environmental model and additional sensor data. The reference path is fed into an enhanced model predictive controller for controlling the torques and forces at the joints of the robot system. In particular, the model predictive controller uses a mechatronic model of the robot to predict future configurations of the robot based on the present configuration of the real robot system. The comparison of the predicted robot behavior within prediction horizon and the reference path is used to optimize the output of the controller. The objective function and soft or hard constraints of the optimization are given by the task-oriented path planner based on the desired task and the current situation of the environment. For example, a stiff end-effector position or compliant joint positions might be the goal of the optimization. Typical constraints are obstacle or singularity avoidance or any other physical constraints. This means that an adaptive behavior of the industrial robot is possible. On the one hand, the robot can be very precise because deviations of the end-effector from its reference position are pre-compensated by using predicted deviations from the mechatronic model. On the other hand, human robot collaboration with a compliant robot behavior is also possible due to a superimposed online task-oriented path planner. 58

59 Session 4: Logistic Concepts and Enabling Technologies 4.9 Industrial Indoor Localization: Improvement of logistics processes using location based services Niklas Hesslein a, Mike Wesselhöft a, Johannes Hinckeldeyn a, Jochen Kreutzfeldt a a Hamburg University of Technology, Hamburg, Germany The increasing digitalization in production and logistics serves as an enabler for manufacturing and transportation companies. Both the networking of machines and the possibility of precise real-time location of mobile actors enables the introduction of so-called Location Based Services (LBS). These services are based on indoor-location, operational and production data to improve internal processes. Due to the large number of possible heterogeneous data sources from a variety of sensors and IT systems and the resulting number of interfaces, the conceptual design of LBS is complex and often somewhat unique for a particular situation. This leads to an increased implementation effort in the real-time operation of the company. Within the framework of the EFRE-funded research project Industrial Indoor-Localization, an open source software standard for environment modeling called RAIL was designed and tested. RAIL acts as a middleware between the data sources and the services, reducing the number of interfaces. Communication takes place by means of a standardized protocol. This protocol enables Location Based Services to allow querying different information quickly. Within the scope of the project, four Services are being developed and exemplary described in this paper. At the beginning, a location-dependent order allocation algorithm was developed for order picking. This reduces the waiting time in narrow-aisle warehouses through prescriptive analysis. Secondly, an order orchestration service was designed that uses the location data for picking control. Furthermore, the last two services are combined in one application. A functional area recognition was developed to support picking. Furthermore, a service for finding points of interest was developed, which includes navigation based on a routing algorithm. Using indoor localization, these services improve the intralogistics processes. These include increasing picking performance or reducing order throughput time by eliminating the need to scan the barcode. Finally, these services increase work safety due to the functional areas, and improve the transparency of the location of points of interest. Session 4 59

60 Session 4

61 Session 5: Sustainability & Energy Efficiency in Production This session highlights new concepts for smart energy storage and management in production. It furthermore considers new approaches for sustainable production equipment strategies. The session concludes with an outlook into business model innovations within automotive manufacturing. 61

62 Scientific Sessions 5.1 FlexPress - An implementation of energy flexibility at shop-floor level for compressed-air applications Can Kaymakci a, Christian Schneider a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany One of the biggest challenges with the growing amount of renewable energy generation is the fluctuation of energy supply. In the case of Germany renewable and volatile generation resources (wind and solar energy) are expanded. Industrial demand side management therefore plays an important role for the automotive industry in Germany with its high-energy demand. For a sustainable production manufacturing processes need to be more energy efficient and adaptable in their energy demand to volatile supply. The main goal is to synchronize manufacturing processes and its energy consumption with the energy supply. While there are holistic concepts and ideas of a service-oriented platform for energy flexibility a defined workflow for implementing energy flexibility signals at shop-floor level is still missing. Our work proposes a method for implementing the workflow to adapt a manufacturing procces in real-time by considering energy flexibility. Therefore the presented method aggregates data from a manufacturing process. Here sensor data intelligently interoperates with flexibility signals on the shop-floor level where an intelligent controller can intervene into process parameters by communicating through an OPC UA Server with the PLC. It is possible to react to external flexibility signals by intervening in the manufacturing process parameters like pressure or pressure flow in a defined flexible window. As a cross-sectoral technology in the automotive industry flexible compressed air is a key enabler for energy-efficient manufacturing. Session Automated environmental assessment via an asset administration shell Anwar Al Assadi a, Lara Waltersmann a, Robert Miehe a, Alexander Sauer ab, Manuel Fechter a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Institute for Energy Efficiency in Production (EEP), University of Stuttgart, Germany Due to growing public awareness and rising requirements of legislation and customers expectations in the field of sustainability, it is increasingly important for enterprises to assess and subsequently reduce their 62

63 Session 5: Sustainability & Energy Efficiency in Production environmental impact. However, the acquisition of environmental data in enterprises still causes considerable effort, due to the necessary manual acquisition. Currently there are only few automated systems, e.g. in the form of energy monitoring systems. Usually, they cannot specify the individual product related footprint in context of the CO2-emissions, energy and resource consumption. Therefore, averaged values are used to evaluate the environmental impact. A unified asset administration shell (AAS) potentially provides higher data transparency and environmental data interoperability along the valueadded chain and, thus a more detailed (real-time capable) accounting of the environmental impact of products and services. The approach represents a promising tool for automated environmental assessments of products and production sites. This paper addresses the following research questions: How can the AAS be used during environmental evaluations? What new data-driven business models will emerge from an automatic environmental assessment? In order to do so, a first application of the AAS for automated environmental assessment was implemented at the ARENA2036 research factory. The AAS automatically collects energy and emission data throughout a production process and thus allows the allocation of real emissions to product and equipment (environmental wallet). The advantages of the AAS in the context of environmental and life cycle assessment in future fluid production systems (FPS) shall be outlined. In addition, first potential business model ideas in environmental data evaluation, analysis and optimization are presented. The presented AAS approach enables an automated product related allocation of CO2-emissions and energy consumption, facilitating individual environmental assessment to address increasing product variety. 5.3 Economic feasibility of highly adaptable production system Urs Leberle a, Yannick-Léon Weigelt a a Robert Bosch GmbH, Robert-Bosch-Campus, Renningen, Germany Session 5 Production companies face a number of challenges caused by an increasingly uncertain market environment, high product variety resulting from individual customer needs and shortened innovation and product life cycles. Adaptable production systems provide an approach to react to short-term changes in demand and to succeed in global competition. Therefore, production resources are no longer used exclusively for one product family or production process, but instead are reconfigured and assigned to new products, processes or technologies repeatedly. 63

64 Scientific Sessions Due to higher initial investment costs it becomes more difficult to assess the profitability of production systems with conventional methods, since the advantages of adaptable production systems are not considered sufficiently. State of the art approaches for planning and assessing adaptable production systems focus on determining the optimal level of adaptability. Based on the assumption of high adaptability leading to high initial investment costs, these approaches reduce costs by limiting the ability to adapt and therefore only consider forecasted impacts on the production environment. This article presents an approach which allows to assess the economic feasibility of highly adaptable production systems, which are reconfigured repeatedly to adapt to products, processes and technologies that are unknown during planning and launch. In contrast to others, this approach considers a preferably high level of adaptability enabling the production system to change extensively and quickly. Reacting to changes faster and with less effort reduces downtime and helps maximizing the overall effectiveness of the production system over the duration of use. Furthermore, the investment decision is based on a product specific configuration state of the system instead of its overall lifetime. This procedure becomes possible due to the high level of adaptability and therefore low costs resulting from adjustments. As a means to test the method a scenario from the publicly funded project Fluid Production is used to find possible fields and borders of application (e.g. internal and external regulations). Session Developing Technology Strategies for Flexible and Changeable Automotive Products and Processes Lukas Block a, Maximilian Jakob Werner a, Matthias Mikoschek b a Institute of Human Factors and Technology Management IAT, University of Stuttgart, Germany b Fraunhofer Institute for Industrial Engineering IAO, Stuttgart, Germany Automotive manufacturers increasingly face the challenge of adapting to new market requirements and economic circumstances within a short time. Both, flexibility in product design and changeability in manufacturing design are of high importance to maintain efficiency in production and react quickly to changing market requirements. Technology intelligence provides the foresight required to anticipate future, innovation-induced changes. Technology scouting and technology roadmaps for example address the emergence of new technologies. Multiple works in literature then investigate the challenge of manufacturing design for flexibility and changeability. However, there is little research, which connects the results of technology 64

65 Session 5: Sustainability & Energy Efficiency in Production intelligence to product development and process design. The approach proposed in this paper fills the void. We develop a methodology and associated process model, which bridges the gap between technology intelligence and action planning to secure flexibility and changeability in products and production. Our technology strategy builds upon the notion and idea of Westkämper et al. (2000) and Hartkopf (2013): Flexibility and changeability is only of value, when transitions in technology occur, which reveal the respective utilities for the utilizing party. In case of a product, the application of a new technology may lead to additional functionalities. New technology in production leverages efficiency in terms of cost, time or quality improvements. Thus, our approach builds upon two methods: One to describe the utility of a new technology and another to determine technology dynamics. A certain notion of functionality then connects the utility-based functionality with the advantage of new technologies across products and manufacturing processes. The methodology is applied to the development of a flexible vehicle platform. It reveals the necessary flexible components and changeable structure with little effort. We show that product flexibility and changeability in this case requires flexibility in manufacturing and argue that this is true for most assembly-focused industries. Thus, the methodology transfers the insights from early technology intelligence into well-defined starting points to pin down flexibility and changeability in manufacturing processes. 5.5 A novel Automated Hardware Upgrade Service for Manufacturing Systems Martin Reisinger ac, Christian Schneider ac, Nicolas Heßberger b, Alexander Sauer ac, Thomas Adolf c a Institute for Energy Efficiency in Production EEP, Stuttgart, Germany b Lumics GmbH & Co. KG, Hamburg, Germany c Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany Energy efficiency has been described as the most important and cost effective means for mitigating greenhouse gas emissions from the industrial service. Despite the importance implementation rates of energy efficiency measures have been described as very low and even a disregard for energy efficiency has been observed. Several of the barriers preventing the implementation of energy efficiency in the industrial context have been identified and structured within a classification. The authors assume that at least some of the observed barriers slowing the implementation of energy efficiency measures (EEMs) can be addressed by increasing transparency Session 5 65

66 Scientific Sessions for the end user during the decision making using means of the so called fourth industrial revolution. We share here the concept of a digital service providing assistance for energy efficient replacement investments of energy consuming physical assets (Hardware) by continuously calculation the lifecycle-costs of the underlying assets and more energy efficient replacement versions (Upgrade). We present the specification for this digital after-sales service and a basic implementation in the context of a use case. The major contribution of this study is to curve out the vision and implementation roadmap for predictive production systems. The predictability of the cyber physical system comes from the predictive analytics for the main components in critical assets, so that unexpected downtime can be reduced and users can act in time to increase productivity. A case study for cyber physical system-enabled ball screw prognostics is presented. 5.6 Robotising, but how? Organisational innovation and heterogeneity in the use of digital production technologies. Evidence from Japanese and German companies in the automotive sector. Guendalina Anzolin ab, Antonio Andreoni b a University of Urbino, Italy b Institute for Innovation and Public Purpose, University College London, United Kingdom Session 5 Building on existing literature focusing on business models, technological change and production organization systems interactions, this paper aims at shedding new lights on the heterogenous nature of technology adoption in the digitalisation era.we draw on a series of semi-structured interviews conducted in 2019, involving more than 40 companies in the automotive sector in South Africa. We analyse how industrial robots are deployed in the automotive sector, and compare the organisational models adopted across several OEMs. We find two distinctive organisational models, the German OEMs (BMW and VW) and the Japanese OEMs (Toyota and Nissan). The four company cases point to dramatic differences in robots adoption, organisational and operational integration, retrofitting of legacy system processes, technology life cycles and performances. This variety of organisational innovation highlights how technology alone does not unleash revolutions, rather it is the heterogeneous strategies of firms, together with the different institutional and social responses to these strategies, that determine revolutions directionality. The case studies point to two main results. First, the introduction of automation technologies increase flexibility. Nonetheless we can identify at least two different types of flexibility, flexible 66

67 Session 5: Sustainability & Energy Efficiency in Production production and flexible automation. We found that the former (the possibility of separating different stages of the production process thanks to both organizational and technological innovations) is integral part of modern car manufacturing, although it is pursued in different ways across OEMs. Instead, flexible automation (the possibility of re-programming automation technologies) is far more present in the Japanese model. Second, our research reveals interesting dynamics between product design and the opportunity to adopt industrial robots. The speed at which companies change their product design influences the organization of their shop floor and their use of industrial robots, which we found to be highly dependent on product design. This aspect was firstly acknowledged from the literature on cellular manufacturing that studied the increase complexity in design and retrofitting aspects in the process from dedicated mechanization to flexible manufacturing. 5.7 New approaches for business model innovation in manufacturing equipment companies Tobias Stahl a, Alberto Mesa Cano a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany Due to shorter life cycles and higher individualization, among other reasons, product requirements have been steadily increasing for years now, influencing manufacturing environments considerably. Some consequences are for example a higher complexity and more frequent reconfiguration of production equipment and systems. This implies the need for a growing number of manufacturing professionals with specialized know-how, that results in high, non-value-added production costs at the same time that it reduces factory adaptability to continuously changing market requirements. Automobile manufacturers see the further modularization and self-integration of manufacturing equipment as some of the most promising approaches to reduce implementation and integration efforts in production, while decreasing the uncertainty in equipment selection. This is also considered an effective way to decrease reconfiguration costs and ultimately increase the versatility of production facilities. The Fluid Production, a joint project within the research campus ARENA2036 that aims at a highly flexible and reconfigurable production system for automotive industry, illustrates this scenario. The top-down production strategy definition by automobile manufacturers and the subsequent implementation by individual manufacturing equipment suppliers are then in conflict with a bottom-up, function oriented integration of Cyber-Physical Production Systems (CPPS). In this Session 5 67

68 Scientific Sessions context, equipment and system suppliers are challenged by new functional demands. However, since equipment integration and reconfiguration activities play a key role in the current business model of most manufacturing equipment suppliers, both in terms of value and revenue, more versatile machines are considered a threat. New business models are therefore required for these companies to meet their customers demands and stay competitive in the long term. This paper identifies concrete promising approaches for manufacturing business model innovation, including lessons learned and best practices from research activities within the ARENA2036. These approaches lead to alternative business models that represent a possible way out of the usual business dynamics between automobile manufacturers and their equipment suppliers, which currently inhibits innovation towards more flexible production systems. Session 5 68

69 Session 6: Body in White & Painting This session addresses current research into metal forming, bonding and painting while also considering fully flexible body-in-white production concepts to encounter volatile market demands. The session ends looking into cleanliness technologies for battery production systems. 69

70 Scientific Sessions 6.1 The fully flexible body shop - a holistic approach for the vehicle production of tomorrow Marcel Todtermuschke a, Alexander Voigt b, Rayk Fritzsche a, Jens Lippmann a a Fraunhofer Institute of Machine Tools and Forming Technology IWU, Chemnitz, Germany b Volkswagen AG, Wolfsburg, Germany Session 6 The growing number of vehicle models in automotive engineering, marketspecific products and simultaneously decreasing quantities per variant make it necessary to design the necessary manufacturing systems universally and, if possible, to adapt them to the changing geometric shapes of components and specific joining task in production cycle. In car body construction, previous approaches to flexibilization have involved the replacement of fixtures, grippers and joining tools. However, due to space constraints, these only allow a limited number of different models per production line (approx. 4-8), which is also associated with cycle time losses due to changing and docking times. The flexibility approach developed between Volkswagen AG and Fraunhofer IWU describes for the first time a holistic solution for this problem. Technical requirements for different equipment as well as a new planning approach are shown, which makes it possible for planner and designer to control the complexity of such systems and to realize individual equipment. It requires at least the knowledge of all variants to be produced on a production line as well as the necessary technologies and process parameters. These requirements can be used to calculate and design a suitable clamping device as well as to configure the required gripping technology on a software-based modular basis. However, the systems are also designed to be adaptable for future product variants. The methodical solution approach worked out in this process is presented as well as a proof of the increased productivity. If aluminium is processed in addition to typical steel materials, special spot welding systems or laser welding systems must be used. Since laserwelding processes has to be carried out in a light-tight closed cell for safety reasons, the use of a laser-welding gun was tested and realised in this project. Considerations of logistics and potentials resulting from the complete data acquisition, for example the exact clamping point position including necessary adjustments from the quality control loop, complete the core of this paper. 70

71 Session 6: Body in White & Painting 6.2 Automated generation of clamping concepts and assembly cells for car body parts for the digitalization of automobile production Markus Till a, Andreas Zech a, Ralf Stetter a a Ravensburg Weingarten University (RWU), Weingarten, Germany A central success factor for the digitalization of production processes is the provision of a consistent database across domains and life cycles. The current situation in the automotive industry is characterized by a multitude of engineering tools with diverse, proprietary data formats, which require complex conversion processes and show dramatic deficits in the consistency and accessibility of the data. In recent years, graph-based design languages have been refined and their range of application expanded to an extent that they represent an interesting approach to addressing these problems. The focus of this paper is on the automated generation of assembly processes and assembly resources (e.g. type-related production equipment such as clamping devices) using the example of automotive body parts (front flap and B-pillar). These examples are use cases of the Center for Applied Research (ZAFH) Digital Product Lifecycle (DiP). The aim of the ZAFH research project is the complete digital representation of the product life cycle. The digital modelling of the product life cycle is implemented by means of a language-based engineering framework consisting of graph-based design languages. Extensive research work has made it possible to map such languages in UML (Unified Modeling Language) and led to the development of a suitable design compiler (DC43, IILS GmbH). A use case within the ZAFH DiP describes the automated generation of the product geometry as well as the associated assembly processes and assembly resources of automotive body components (e.g. a front flap and B- pillar). Within the framework of automated production planning, clamping concepts and assembly cells (with automated wiring) are generated using graph-based design languages. Based on the manufacturing concept, a joining sequence and fastener planning is carried out, from which a productspecific clamping and fixing concept is derived. The central advantage of this procedure is, in addition to the high degree of automation, the possibility of providing a consistent database. This database allows the automatic derivation for the various specialized engineering tools. Session 6 71

72 Scientific Sessions 6.3 Adjustable Hemming Die Arndt Birkert a, Moritz Nowack b a inigence gmbh, Bretzfeld, Germany b Zentrum für Umformtechnik und Karosseriebau, Heilbronn University of Applied Sciences, Heilbronn, Germany The Center for Forming Technology and Car Body Engineering at the Heilbronn University conducts research and development in the field of dimensional car body accuracy. It s well known among experts that there are only poor options to influence the dimensional accuracy of car body hang-on parts in the body shop. As a consequence expensive tool changes of the stamping tools are usually necessary to make the parts perfectly fit into the car body. The doors and closures of a car body mostly consist of sheet metal stampings, namely an inner part and an outer skin part, which quite often are being joined by roller hemming. During the stamping process of these parts spring-back effects occur. Thus the stampings do not exactly correspond with their target geometry. Such deviations of the stampings from their target geometry as well as further changes of dimension and shape in the subsequent hemming process are finally causing deviations of the final assembly from its target geometry. These deviations in turn have a negative impact on the fitting accuracy of the assembled part in the car body. Concrete results are varying gap widths and transition offsets between the respective part and its neighbor part. Tool changes of the stamping tools in order to eliminate these defects are still time and cost consuming and thus shall be reduced to a minimum. The adjustable hemming die which is presented here enables the adaption of the inserting and clamping situation of the stamped parts before and during the roller hemming process so that the dimensional accuracy of the respective assembly especially with regard to any transition offset defects can be significantly influenced and thus be improved during the series launch as well as in series production. By using the adjustable hemming die, especially the transition areas of assembled parts can be changed by up to 2 mm and more at lowest expense within only a few hours. Session 6 72

73 Session 6: Body in White & Painting 6.4 Modelling Defects of Unhardened Adhesives Resulting from Handling and Warpage: Viscous Fingering Silvio Facciotto a, Daniel Sommer a, André Haufe b, Martin Helbig b, Peter Middendorf a a Institute of Aircraft Design, University of Stuttgart, Germany b DYNAmore GmbH, Stuttgart, Germany Adhesive bonding of hybrid, multifunctional parts is key to a modern, efficient body in white in automobile production. It enables lightweight design, multi-material constructions and leads to a stiffer behaviour of the chassis. However, mechanical joints are often additionally required to ensure the integrity in case of failure of the adhesive bond; e.g. to stop catastrophic zipper-like failure of a bonded seam. Only some of these joints are placed in the early stages of the production chain in order to fix the parts whilst the adhesive is uncured. In this state, robots transport the parts from station to station at high speeds and accelerations. Additionally, when curing the adhesive in a run-trough oven, along with the electrophoretic-deposition coating, the complete assembly is heated above curing temperature. Because of deformation induced by handling and temperature expansion, displacement of the joining partners relative to each other can occur, which may result in defects in the adhesive bond and possibly lead to failure. One important effect is viscous fingering or Saffman-Taylor instability, which can occur in any unstable interface between two fluids (here: the adhesive and the surrounding air). The result is a reduced area of the adhesive with fractal-like fingers protruding from the exposed surfaces. This phenomenon occurs when the uncured glue is strained and the aspect ratio of the bond line exceeds a specific range. This paper focuses on capturing this effect within a finite element process simulation in order to give predictions on its occurrence and extent. The modelling of the adhesive with a hyper-elastic model is discussed and a sensitivity study of simulation parameters on the effect is presented. Virtual specimens include round geometries, which can be compared to tests in Lifting-Hele-Shaw-Cells, and long bond lines similar to those used in automobiles. An outlook on the calibration of the numerical model to the aforementioned tests and on transfer to structural rupture simulation of the damaged, hardened adhesives is given. Session 6 73

74 Scientific Sessions 6.5 A self-programming painting cell SelfPaint : Simulation-based path generation with automized quality control for painting in small lot sizes Nico Güttler a, Niklas Sandgren b, Stefan Weber c, Philipp Knee a, Raad Salman b, Jens Klier c, Fredrik Edelvik b, Oliver Tiedje a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany b Fraunhofer-Chalmers Centre, Gothenburg, Sweden c Fraunhofer Institute for Industrial Mathematics ITWM, Kaiserslautern, Germany Session 6 The increasing variety of products and variants requires a flexible and fast path generation in robot-based painting processes. In the state of the art, path generation in the painting industry is a time-consuming and cost-intensive iteration process in which the generated paths are evaluated and optimized via painting trials. In this paper, we present a concept for a self-programming painting cell, which is based on the key technologies 3D-scanning, multi-physics painting simulations, and a contactless film thickness measurement using terahertz technology. The core-element of this cyber-physical painting system is a unique combination of numerical painting simulations with a gradient-based multi-objective optimization method, which virtually computes painting paths utilizing a CAD model fitted onto the point cloud of the scanned workpiece. In order to drastically reduce the time and computationally intensive numerical fluid dynamic simulations, a step-by-step coupling of an offline and online simulation was implemented. In a final step, a guaranteed collision-free robot motion without singularities is generated automatically from the painting path. The concept was validated under pilot plant conditions by the painting of a fender using electrostatically assisted high-speed rotary bell atomizer based on the measured paint film thickness. The coating thickness, measured with terahertz radiation was used as the target and validation criterion, as it shows a strong correlation to other quality values. The results show that the achieved film thickness was within the process specification, although deviations between simulated and measured film thicknesses were found in the edge zones of the workpiece.the self-programming painting cell Self- Paint was successfully validated conceptually under pilot plant conditions. However, process integration of SelfPaint is still limited in the process planning itself since prerequisites for working with optical devices, as well as a time window for the calculation of painting paths, must be taken into account. 74

75 Session 6: Body in White & Painting 6.6 Less chemicals and more power: Pulsed Electric Field (PEF) treatment for reduction of microorganisms. A biocide-free bath maintenance method in pretreatment of dip coating plants. Philipp Preiß a, Claus Lang-Koetz a, Wolfgang Frey c, Monika Bohem b, Norman Poboß b, Stefan Dekold b a Institute for Industrial Ecology (INEC), Pforzheim University, Germany b Eisenmann Anlagenbau GmbH & Co. KG, Böblingen, Germany c Institute for Pulsed Power and Microwave Technology (IHM), Karlsruhe Institute of Technology (KIT), Germany Decisions on the implementation of innovative concepts and technologies into automotive pretreatment lines are regularly marked by uncertainty regarding trade-offs between economic, ecologic and technical aspects. Huge amounts of water are consumed during the production in car body painting plants. It is hardly possible to avoid that certain microorganisms (MO) proliferate in process water and pretreatment bath tanks. If the bacterial load increases too much, the quality of the paint finish is likely to be impaired. Therefore, chemical biocides are regularly used in pretreatment and dip coating plants. However, repeated use of the same biocides can lead to resistance of some MO strains. In addition, stricter legislation is gradually withdrawing certain biocides from the market and making it more difficult to obtain approval for newly designed active substances. Hence, conventional decontamination methods might no longer work in the future. The PEF treatment is an innovative technology within the field of pretreatment lines. By applying high voltage pulses (kv range, µs duration), a high field strength is generated in the process fluid and across the cell membrane of the MO, which permeabilises the cell membrane. As a result, the MOs lose their cell interior (cytoplasm) and eventually die. In the BMBF-funded joint-venture project DiWaL, this physical decontamination method is applied for the first time to treat paint solutions and water from the dip coating process. A 30 kv demonstration plant was built up and tested. A semiconductor switched pulse generator provides the necessary flexibility to control the pulse height and duration. The ecological and economic sustainability was enhanced by stakeholder integration, economic and ecologic analysis, and corresponding feedback and interaction with the developers of the technology. The results of the project show that PEF treatment has a high market potential and several advantages regarding digitalization and process control, compared to conventional biocide treatment. With regard to the ongoing energy transition, the environmental impacts are expected to decrease in the near future. Session 6 75

76 Scientific Sessions 6.7 Safety in electromobility Technical cleanliness between the poles of design requirements and efficient production Patrick Brag a, Markus Rochowicz a a Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany The amount of automotive electronics is constantly rising for years. A sudden rise can be partially observed through the electrification in the powertrain and automation of driving functions. Particles from production can constitute a substantial risk in regard of function and security for the built-in systems such as batteries, fuel cells, control and power electronics up to camera systems. Conductive particles can cause false signals in electronics or even severe short-circuits up to vehicle fire in high-voltage or battery applications. But also non-conductive, microscopic impurities can also cause optical errors and failures in camera systems. Thus technical cleanliness of components and production processes is an increasingly important quality characteristic in the automotive value and supply chain. A very urgent problem at the moment is the divergence between very high cleanliness limits - usually prescribed by the development - and the technical and economic limits in mass production. This article presents current and future approaches that can help determine or implement the right level of cleanliness: - Design principles to reduce particle sensitivity, which can be already considered during the design phase. - Integration of technical cleanliness in the product development process, supported by suitable FMEA and audit tools. - Methods to evaluate the actual damage potential or failure risk due to particles, both theoretically and experimentally (current research topics), in order to derive realistic and economically feasible cleanliness limits. Session 6 76

77 Session 7: Smart Systems & Services in Manufacturing This session takes a look into current research for deeplearning in production, robotics, the appropriate use of wearables, predictive maintenance and digital twin technologies. 77