Matthias Brossog

An Integrated Simulation Approach to the Development of Assembly System Components

Commonly, a modelling and simulation approach is used for parameter optimization and system behavior analysis of assembly system components. However, such simulation approaches are often not well integrated or its analysis is still based on a specific physical domain. This paper proposes an integrated simulation approach that can be used for designing, analyzing and optimizing the entire physical domain as well as the control system of mechatronic components in an assembly system. The state-of-the-art, requirements, our concept and the limitations of an integrated simulation approach are explained in this paper. A case study of the development of conveyor systems using the multi-domain simulation tool OpenModelica is also presented. On-going research shows that the integrated approach offers various benefits such as reduced development time and minimized errors, as well as maintenance during the commissioning process.

Virtual Validation of the Manual Assembly of a Power Electronic Unit via Motion Capturing Connected with a Simulation Tool Using a Human Model

A key challenge for gaining important time and cost potentials in production engineering projects is an early virtual validation during the pre-series. Under the premise to replace physical by digital mock-ups, we will present requirements and solutions of a virtual validation focused on manual assembly of power electronics in automotive industry. Using a digital human model for dynamic analysis is not very prevalent, because of the high modeling complexity in the digital environment. The resulting motions of the human model are furthermore unrealistic. Hence the need for research is a time saving and, regardless, a realistic movement design for virtual validation by a human model. To achieve this goal, we use an experimental setup including a variable eight camera motion capture system, a data glove and an interface for the connection to the digital validation software.

Mechatronic Behavior Analysis of a Customized Manufacturing Cell

Analyzing the mechatronic behavior of a manufacturing cell used in a customized manufacturing process is a difficult task with numerous obstacles. Therefore, a method that can be easily used for developing and optimizing a customized manufacturing cell, i.e., universal contacting module (UCM) cell, for the in-circuit testing of electronic modules is desired. In this paper, we present a convenient method using multi-domain simulation tools for analyzing the mechatronic behavior of the UCM cell. The UCM cell, which consists of mechatronic components such as a six-axis industrial robot and conveyor systems, were successfully modeled, simulated, and validated under several payloads. This work also presents a modeling procedure that can be applied by system engineers with a basic background in control systems for analyzing the mechatronic behavior of manufacturing cell components.

Green Energy Management Portal – Knowledge and Project Management for Energy Efficiency Projects

Due to increasing cost pressure and competition on the market resource and energy efficient production is inevitable. Energy efficiency projects address this issue through identifying and unleashing energy saving potentials. Green Factory BAVARIA as an institute-spanning research cooperation generates numerous innovative solutions for energy efficiency enhancement in the manufacturing industry through its research projects. Furthermore a great range of energy efficiency measures yet exist. However, when introducing or developing measures for energy efficiency optimization, there is a lack of systematic knowledge and project management, especially in academic research projects. Systematic project management has been established in industry for several years. There are numerous successful examples given in product development as well as in event preparation or reorganization projects. Thus the implementation of systematic project management in universities is essential, precisely because there often is a close cooperation with the industry in particular in the technical and scientific fields. The more widespread the cross-links between the universities are and the more cooperation partners are involved, the more urgent project management tools are required. In this paper we introduce Green Energy Management Portal, a communication and collaboration platform providing both methods and workflows for conducting research projects on energy efficiency as well as a knowledge base for energy efficiency measures. Therefore Green Factory BAVARIA is able to meet its aspiration for transferring knowledge about energy efficiency into industry and thus contributes to a greener Bavarian economy.

Motivation and Approach to Establish a Comprehensive Community in Project Engineering

Project engineering covers all technical related activities, processes and tools to realize a customer specific solution (e.g. industrial plant or factory) from conceptual design to commissioning. Consequently, project engineering deter-mines both, costs and quality of customer-specific projects. Due to growing com-plexity of industrial projects and rising cost pressure caused by new players in the market, companies specialized on project engineering have to improve quality and reduce costs of their engineering results continuously. This paper shows how engineering companies can be supported in mastering these challenges by joining together in an ‘Engineering Community’. Therefore, a community model consisting of the three key variables ‘content & activities’, ‘stakeholders’ and ‘infrastructure’ has been developed.

Dreidimensionale Planung, Simulation und Überwachung von Produktionssystemen mit VRML

Kurzfassung Der Einsatz frei zugänglicher und kostengünstiger Technologien für die Entwicklung von rechnerunterstützten Werkzeugen zur Unterstützung von Planern, Herstellern und Betreibern von Produktionsanlagen bietet ein großes Potenzial zur Effizienzsteigerung vor und während des Anlagenbetriebs. Der vorliegende Artikel zeigt mehrere Ansatzpunkte für den gewinnbringenden Einsatz der VRML-Technologie am Lehrstuhl FAPS der Universität Erlangen auf. Ähnlich wie bei der webbasierten Layoutplanung bildet diese Form der 3D-Beschreibung ebenso die Basis für weitere Umsetzungen im Bereich der webbasierten Simulation. Des Weiteren wurden eine Zustandsüberwachung von Produktionsanlagen im Rahmen eines Telemonitoring-Systems sowie eine webbasierte Visualisierung der Ablaufsimulation realisiert.

An Artificial Intelligence Approach for Online Optimization of Flexible Manufacturing Systems

This paper addresses the problem of efficiently operating a flexible manufacturing machine in an electricity micro-grid featuring a high volatility of electricity prices. The problem of finding the optimal control policy is formulated as a sequential decision making problem under uncertainty where, at every time step the uncertainty comes from the lack of knowledge about fu-ture electricity consumption and future weather dependent energy prices. We propose to address this problem using deep reinforcement learning. To this purpose, we designed a deep learning architecture to forecast the load profile of future manufacturing schedule from past production time series. Combined with the forecast of future energy prices, the reinforcement-learning algorithm is trained to perform an online optimization of the production ma-chine in order to reduce the long-term energy costs. The concept is empirical-ly validated on a flexible production machine, where the machine speed can be optimized during the production.

Development of an ontology-based competence management system

The work of research institutes in the field o! engineering is characterized by a work-sharing fulfillment o! knowledge-intensive tasks. For the success of these institutes, it is of great importance that this knowledge is properly networked. In order to improve this and to develop the competences of institutes a competence management system is created that comprehends all competences available, makes them plausible, facilitates competence retrieval and supports a competence exchange. In this paper we propose an approach for capturing, structuring and visualizing competences. This approach can be used for both research facilities and companies in general. Moreover, we show how the competence data is integrated into an ontology-based competence management system. This also includes the connection between the ontology in the backend and the graphical user interface, being created in SharePoint.

Semantic Meta Model for the Description of Resource and Energy Data in the Energy Data Management Cycle

Energy efficiency is a critical competitive factor. Transparency of energy consumption is the key for increasing efficiency of production. For this purpose, existing energy data management systems collect data such as power, gas or water consumption on field level, save them in databases, and aggregate them in reports. However, the identification of saving potentials and the definition of efficiency measures is carried out by energy experts and thus is dependent on a person’s knowledge. The documentation of knowledge about saving potentials and measures does not take place and relations among data and knowledge of various domains are not captured. In this paper, we provide an approach that allows the holistic capture and description of data and knowledge relations. Through the use of an ontology-based meta model, consumption data can be augmented with information about time and place of capture, data type, intended purpose and permissions, as well as interfaces to other systems and relations to knowledge elements. The semantic model is to capture relevant requirements of all information demanders within the energy data management cycle. Therefore, the model is capable of detecting efficiency deficits and retrieving relevant energy efficiency measures within a knowledge base. Thus, energy consumption data can be efficiently used and knowledge about efficiency can be sustainably preserved.

A Model-Based Approach for the Energy Monitoring of Handling Machines

An energy-efficient handling system can only be constructed on condition that at the beginning of the development process the energy behavior of handling machines can be evaluated. However, the challenge at the beginning of the development is characterized by the fact that there is no energy data of these machines available. Most of the machine manufacturers do not provide such data or they only offer general data, which is limited to special machine conditions or movements. To solve this challenge, a model-based approach for energy monitoring of handling processes is developed. This approach allows the planning engineers to analyze the energy behavior as well as the kinematic behavior of handling machines at their real conditions. The approach is developed using the multi-domain simulation method, so the detailed components of handling machines can be modeled and simulated. Based on the case study analysis that was performed on a Cartesian robot, the developed approach is conveniently used to predict the energy consumption behavior of handling machines. Thus, using the developed approach, a planning engineer can reduce the energy consumption of handling systems by optimizing the handling sequence.