Advances in Automotive Production Technology – Theory and Application (eBook)

Editorial 6
Contents 8
Part A New Approaches for Efficient Production and Assembly Planning 14
Agile Hybrid Assembly Systems: Bridging the Gap Between Line and Matrix Configurations 15
1 Introduction 16
2 Theoretical Background 16
3 A Framework for Agile Hybrid Assembly Systems 17
4 Use Case Development 20
5 Conclusion 21
References 22
Economic Feasibility of Highly Adaptable Production Systems 24
1 Introduction and Motivation 24
2 State of the Art 24
3 Approach 25
4 Example of Application 27
5 Discussion and Evaluation 29
6 Summary and Outlook 30
References 30
Reconfiguration of Production Equipment of Matrix Manufacturing Systems 32
1 Introduction and Motivation 32
2 Changeability of Matrix Manufacturing Systems 33
3 Continuous Adaption of Production Entities 35
4 Approach to Reconfigure MMS 36
5 Conclusion and Outlook 37
References 38
A User-friendly Planning Tool for Assembly Sequence Optimization 40
1 Introduction and Fundamentals 40
1.1 Graph-based Design Languages 40
1.2 Representation of Assembly Systems 41
1.3 Petri Nets 41
2 Implementation 43
2.1 Graphical User Interface 43
2.2 Graph-based Design Language for Assembly Planning 44
2.3 Workflow 45
3 Application Example 46
4 Summary and Discussion 47
References 48
Fluid Manufacturing Systems (FLMS) 49
1 Introduction and Motivation 49
2 State of the Art 50
3 Definition of Fluid Manufacturing Systems (FLMS) 52
4 Conclusion 55
References 56
Automated Environmental Impact Assessment (EIA) via Asset Administration Shell 57
1 Introduction 57
2 State of the Art 58
2.1 Environmental Impact Assessment (EIA) Within Enterprises 58
2.2 Usage of AAS 59
2.3 AAS in the Context of EIA 59
3 Implementation of the AAS for EIA 60
4 Result 60
5 Discussion 61
6 Summary and Outlook 62
References 63
Business Model Innovation in Manufacturing Equipment Companies 65
1 Introduction 65
2 Approaches to Business Model Innovation 66
2.1 Need for Business Model Innovation 66
2.2 Screening of Business Model Patterns 67
2.3 Requirements of Reconfigurable Production Systems 68
2.4 Problem-Solution Fit 70
3 Feedback Within ARENA2036 and Final Discussion 71
4 Summary 72
References 72
Identification of Reconfiguration Demand and Generation of Alternative Configurations for Cyber-Physical Production Systems 75
1 Introduction 75
1.1 Requirements for the Self-organized Reconfiguration Management 76
1.2 Basic Concept and Focus of this Contribution 77
2 Related Work 77
3 Identification of Reconfiguration Demand and Generation of Alternative Configurations 78
3.1 Identification of Reconfiguration Demand 78
3.2 Generation of Alternative Configurations 79
4 Proof of Concept 80
5 Conclusion and Future Work 81
References 81
Method for Data-Driven Assembly Sequence Planning 83
1 Introduction 83
2 Approaches in the Field of Automatic Assembly Planning 84
3 Method to Generate Optimized Assembly Sequences from Actual Data 85
3.1 Context 85
3.2 Data Analysis 85
3.3 Example 88
4 Conclusion and Outlook 89
References 91
Evaluation of Material Supply Strategies in Matrix Manufacturing Systems 92
1 Introduction 92
2 State of the Art 93
2.1 Material Supply 93
2.2 Matrix Manufacturing System 93
3 Material Supply in the Context of MMS 95
3.1 Challenges to Material Supply 95
3.2 Methodology of Evaluating the Suitability 95
3.3 Evaluations 96
4 Findings 98
5 Conclusions & Outlook
References 99
Smart Factory and the Unique Digital Order Twin 101
1 The Idea of a Digital Order Twin 101
2 Repository – Main Databases for the Digital Order Twin 103
2.1 Production and Material Flow Structure of a Smart Factory 103
2.2 Product Structure and Bill-Of-Material in a Smart Factory 103
2.3 Unique BoM and Semantic Product Memory of Final Products 104
3 Regulation and Ordering of Final Product and Components 105
3.1 The Role of ‘Order-Entry Point’ in a Smart Factory 105
4 Conclusion and Short Outlook 106
References 107
Developing Technology Strategies for Flexible Automotive Products and Processes 109
1 Introduction 109
2 Theoretical Background 110
3 Approach and Methodology 111
3.1 Assessing Latent User Needs of Future Product Functions 113
3.2 Estimating Technology Dynamics 113
4 Application and Results 114
5 Discussion and Conclusion 116
References 117
Structured Information Processing as Enabler of Versatile, Flexible Manufacturing Concepts 120
1 Introduction 120
2 State of the Art and Related Work 121
2.1 Efforts Towards Implementing Alternative Manufacturing Concepts for Modern Production Systems in the Automotive Industry 121
2.2 Distributed Information Processing as Requirement for Implementing Modular Production Systems 122
3 Concept for Information Processing in Alternative Versatile Manufacturing Systems Implementation 122
3.1 Requirements for Information Processing in Modular Production Systems 123
3.2 Structuring of the Information Flow of Entities 124
4 Discussion and Conclusion 126
References 127
A Novel Approach to Generate Assembly Instructions Automatically from CAD Models 129
1 Introduction 129
2 State of the Art in the Generation of Assembly Instructions 130
3 Interface to CAD Model 131
4 Assembly Sequence Generation 132
5 Generation of Assembly Instructions 133
6 Validation 134
7 Conclusion 136
References 136
Selective Assembly Strategy for Quality Optimization in a Laser Welding Process 138
1 Introduction and Problem Setting 138
1.1 State of the Art of SA and Deficits of Current Approaches 139
1.2 Objectives and Scope of this Paper 141
1.3 Description of the Use Case and Problem Setting 141
2 Experimental Realization of the Selective Assembly 142
2.1 Mathematical Statement of the Optimization Problem 142
2.2 Optimization Settings and Parameter Study 143
2.3 Results 144
3 Conclusion and Outlook 144
References 145
FlexPress – An Implementation of Energy Flexibility at Shop-Floor Level for Compressed Air Applications 147
1 Introduction 147
2 Related Work 148
3 Case Study 149
3.1 Use Case 149
3.2 Proposed Method for Flexibility Modeling 150
3.3 Flexibility Model for Compressed Air 151
4 Results and Discussion 152
5 Conclusion 153
References 153
Part B Smart Production Systems and Data Services 154
A Framework for Digital Twin Deployment in Production Systems 155
1 Introduction 155
1.1 Production Systems 156
1.2 Related Work 157
1.3 Contribution 157
2 Digital Shadow 157
3 Digital Twin 159
4 Integration in Automation Process 161
4.1 Feedback to Physical World 161
4.2 Integration with MES/ERP 161
5 Conclusion 162
References 162
Assets2036 – Lightweight Implementation of the Asset Administration Shell Concept for Practical Use and Easy Adaptation 163
1 Motivation 163
2 Introduction and State of the Art 164
3 Use Case and Derived Requirements 165
4 Concept and Implementation of Assets2036 165
4.1 Concept 165
4.2 Submodel Description Format 167
4.3 Implementation of Communication Using MQTT and JSON 167
4.4 Example 168
5 Conclusions 169
References 170
AutomationML in Industry 4.0 Environment: A Systematic Literature Review 172
1 Introduction 172
2 AutomationML Overview 173
3 Methodology and Discussion 174
4 Conclusion and Outlook 177
References 177
Generic and Scalable Modeling Technique for Automated Processes 180
1 Introduction 180
2 Theoretical Basis 181
2.1 Petri Nets 181
2.2 Refinement Action Engine 181
2.3 Utlized Control Hardware in Production Systems 181
3 Approaches utilized by Research and Industry 182
3.1 Modelling Techniques in Industry 182
3.2 Approaches in Research 182
4 Research Needs 182
5 Methodology 183
6 Application of the Methodology 184
6.1 Description of the use Case 184
6.2 Modelling the System 185
6.3 Operation of the Assembly System 186
7 Conclusion and Outlook 186
References 187
On Automation Along the Automotive Wire Harness Value Chain 188
1 Introduction 188
1.1 Current Wire Harness Design 188
2 Wire Harness Design Automation 189
2.1 Automation Approach 189
2.2 Use Case 190
2.3 Data 190
2.4 Process 191
2.5 Assembly Simulation 194
2.6 Reduction of Design Time and Design Cost 194
3 Summary and Outlook 194
References 195
An ISA-95 based Middle Data Layer for Data Standardization—Enhancing Systems Interoperability for Factory Automation 197
1 Introduction 197
2 Motivation and Problem Statement 199
3 Approach 200
3.1 Main idea 200
3.2 Data Architecture Design 201
4 Case Study 202
4.1 Data Model Analysis 202
4.2 Data Model Mapping 202
5 Conclusions 203
References 204
Deep Reinforcement Learning for IoT Interoperability 205
1 Introduction 205
2 Background 206
2.1 Related Work and own contribution 207
3 Experimental Setup 207
4 DRL Policy and Learning Algorithm 208
5 Results 210
6 Conclusion and Outlook 212
References 212
Wireless Industrial Networks for Real-Time Applications 215
1 Introduction and Motivation 215
2 Wireless Transmission Systems 216
3 Ultra-reliable Wireless Industrial Network 217
3.1 Physical Layer 219
3.2 Media Access and Coexistence Management 219
4 UWIN Implementation and Prototypes 220
5 Summary and Outlook 221
6 Acknowledgements 222
References 222
A Novel ‘Automated Hardware Upgrade Service’ for Manufacturing Systems 223
1 Introduction 223
2 Current State of Research 224
3 Automated Hardware Upgrade Service 226
4 Case Study 227
5 Conclusion and Outlook 228
References 229
Deep Learning-Enabled Real Time In-Site Quality Inspection Based On Gesture Classification 231
1 Introduction 231
2 Related Work 232
3 Overall Framework 233
3.1 BIOX Bracelet Implementation 233
4 Data Pre-processing 234
5 Deep Learning Model for Classification 236
6 Results 236
7 Conclusion 238
References 238
Detection and Monitoring for Anomalies and Degradation of a Robotic Arm Using Machine Learning 240
1 Introduction 240
2 Data Description 242
3 Methodology 242
4 Results 244
5 Conclusion 246
References 247
Using Deep Neural Networks to Separate Entangled Workpieces in Random Bin Picking 248
1 Introduction 248
2 State of the Art 249
3 Proposed Separation Methods 249
3.1 Method to Validate the Effort of Separation in Simulation 249
3.2 Three Proposed Separation Strategies 251
4 Training of a Serial Connection of CNNs 252
5 Results 253
5.1 Selection of Proposed Separation Strategy 253
5.2 Validation of Predicted Path Points with Strategy A 253
6 Integration in Bin Picking Application 254
7 Conclusion and Outlook 255
References 256
Automatic Grasp Generation for Vacuum Grippers for Random Bin Picking 257
1 Introduction 257
2 Related Work 258
3 Probability Matrix of a Successful Grasp 258
3.1 Projection of Workpiece and Gripper 258
3.2 Overlap Between Workpiece and Gripper 259
3.3 Calculation of Center of Gravity Heatmap 260
3.4 Calculation of Surface Smoothness 261
3.5 Weighted Combination and Normalization of Matrices 261
4 Grasps Generation and Gripper Selection 262
4.1 Gripper Selection 262
4.2 Generation and Prioritization of Grasps 262
5 Experiments and Results 262
5.1 Hardware Testing Setup 262
5.2 Evaluation of Grasp Reliability and Gripper Selection 263
6 Conclusion 264
References 264
Flat Knitted Sensory Work Glove for Process Monitoring and Quality Assurance 266
1 Introduction 266
2 Materials and Methods 268
2.1 Sensor Construction 268
2.2 Sensor Characterization 270
3 Conclusion 272
4 Acknowledgement 273
References 273
Predictable and Real-Time Message-Based Communication in the Context of Control Technology 274
1 Introduction 274
2 Related Works 275
3 Concept to fulfill real-time requirements 275
4 Validation 278
5 Conclusion 280
References 281
Part C Advances in Manufacturing Processes and Materials 282
A New Adjustable Hemming Die for Automotive Body Construction: Simulation, Design and Experiments 283
1 Introduction 283
2 FE-Based Optimization of Hang-On Parts by Modification of the Active Surface of a Virtual Hemming Die 284
3 Construction of an Adjustable Hemming Die 288
4 Validation of an Adjustable Hemming Die Prototype for the Manufacturing of an Engine Bonnet 290
5 Summary and Conclusion 292
References 293
Production of Thin Outer Skin Car Body Panels by Using Novel Short Cycle Stretch-Forming (SCS) Technology 294
1 Introduction and State of the Art 294
2 Short Cycle Stretch-Forming (SCS) 295
2.1 Basic Function of SCS-Technology 295
2.2 Experimental Research and Validation of Simulation 295
2.3 Close-To-Production Tool Concept and Improved Sheet Metal Part Properties 297
2.4 Energy Saving Potential of the SCS-Process 299
3 Conclusions 299
References 300
Automated Generation of Clamping Concepts and Assembly Cells for Car Body Parts for the Digitalization of Automobile Production 301
1 Introduction 301
2 State of the Art 302
2.1 Graph-Based Design Languages 302
2.2 Product Development Process and Geometric Modeling 303
3 Methodology 303
4 Results and Discussion 305
4.1 Central Data Model 305
4.2 Design Variants 305
4.3 Automated Wiring 306
5 Summary and Outlook 306
References 308
A self-programming painting cell SelfPaint: Simulation-based path generation with automized quality control for painting in small lot sizes 310
1 Introduction 311
2 Input Database 312
3 Module 1: 3D-Scanning 313
4 Modules 2 and 3: Path Generation and Painting 314
5 Module 4: Contactless Quality Control of Paint Film Thickness 316
6 Conclusion 317
References 318
Less Chemicals and More Power: Pulsed Electric Field-Treatment for Reduction of Microorganisms 319
1 Introduction 320
1.1 The DiWaL Project of BMBF 321
2 Pulsed Electric Field-Treatment 321
2.1 Technical PEF-Concepts and New Developments 322
2.2 Results and Evaluation 322
2.3 Integrated Sustainability Assessment of PEF-Treatment 323
3 Conclusion and Outlook 324
References 325
Safety in Electromobility – Technical Cleanliness Between the Poles of Design Requirements and Efficient Production 327
1 Introduction 327
2 Status Quo 328
3 Current Approaches: Product Design 329
4 Current Approaches: Production 330
5 New Approach: Fault Injection Test procedure 331
6 Conclusions 334
References 334
Highly Integrative Rear End Concept of Battery Electric Vehicles 335
1 Introduction 335
2 State of the Art 336
2.1 Battery Design 336
2.2 Multi-material-Design 336
3 Design 337
4 Design and Manufacturing Process 339
4.1 Highly Integral Part Design 339
4.2 Manufacturing Process 340
5 Evaluation of the Highly Integrative Rear End Concept 341
6 Conclusion and Outlook 341
References 342
Modelling Defects of Unhardened Adhesives Resulting from Handling and Warpage 343
1 Introduction & State of the Art
2 Physical Parameters Affecting the Instabilities 345
3 Virtual Prognosis of Instabilities in Uncured Adhesives 346
3.1 Choosing the Modelling Strategy 346
3.2 Selection of Suitable Material Models 346
3.3 Simulation Setup and a Study of Convergence and Aspect-Ratio 347
4 Loaded Uncured Adhesive Bondlines in Automobiles 349
5 Conclusions and Outlook 349
References 350
Experimental Study on Depth of Cure During UV-Post-Curing of Photopolymers Used for Additive Manufacturing 351
1 Introduction 351
2 Experimental 352
2.1 Design of Experiment 352
2.2 Materials 353
2.3 Test Specimen Production and Post-Curing 353
2.4 Hardness Testing 354
2.5 Transmission Measurements 354
3 Results and Discussion 354
3.1 Determination of the Depth of Cure 354
3.2 Results DoE 356
3.3 Results Transmission Measurements 357
4 Conclusion 357
References 358
Simulation Supported Manufacturing of Profiled Composite Parts Using the Braiding Technique 359
1 Introduction 359
2 Experimental Characterization 361
2.1 Investigation on Flat Specimens 361
2.2 Manufacturing and Investigation of a Generic Structure 362
3 Predictive Simulations Within a Closed Process Chain 363
3.1 Digital Twin 363
3.2 Prediction of Material Properties with a Mesoscopic Approach 364
3.3 Virtual Process Window 365
4 Conclusion and Outlook 367
References 367
A New Concept for Producing High Strength Aluminum Line-Joints in Car Body Assembly by a Robot Guided Friction Stir Welding Gun 369
1 Introduction 370
2 Literature Review 371
3 Solution Approach 372
4 Experimental Studies 373
5 Results and Discussion 375
6 Conclusion and Outlook 375
References 376
Multi-robotic Composite Production of Complex and Large-Scaled Components for the Automotive Industry 377
1 Introduction 377
2 Advanced Ply Placement 378
3 Analytical Layup Comparison 380
4 Cost-Benefit Analysis 381
5 Results and Summary 383
References 384
Integrated Machining, Quality Inspection and Sealing for CFRP Components 385
1 Introduction 385
2 Fiber Dust Protection and Collection 386
3 Process Steps 387
3.1 Machining 387
3.2 Brushing and Cleaning 388
3.3 Inspection 389
3.4 Sealing and Curing 390
4 Summary and Conclusions 391
References 392
A Universal Machine: Enabling Digital Manufacturing with Laser Technology 394
1 Introduction 394
2 Laser Materials Processing 395
2.1 Current State of Technology in Industrial Manufacturing 397
3 Current Need for Further Research and Development 398
4 Conclusions and Outlook 400
References 400
Advancing from Additive Manufacturing to Large-Scale Production of Face Shields During the COVID-19 Pandemic 402
1 Introduction 402
2 Manufacturing and Design Approach 403
3 Materials 404
4 Manufacturing Technologies and Designs 405
4.1 Fused Filament Fabrication (FFF) 405
4.2 Screw Extrusion Additive Manufacturing (SEAM) 406
4.3 Laser Cutting (LC) 407
4.4 Injection Moulding (IM) 407
4.5 Folding (FO) 408
5 International Distribution of Face Shields 409
6 Conclusions 410
References 411
Part D New Concepts for Autonomous, Collaborative Intralogistics 413
Towards an Artificial Perception Framework for Autonomous Robots in Logistics 414
1 Introduction 414
2 Motivation 415
2.1 Robotics in Logistics 415
2.2 Towards Intelligent Machines 416
3 Related Work 417
3.1 Perception for Autonomous Driving 417
3.2 Perception for Service Robotics 417
3.3 Perception for Industrial and Logistics Robotics 417
4 Problem Formulation and Objective 418
5 Artificial Perception Framework for Autonomous Robots in Logistics 418
6 Conclusion and Future Work 420
References 420
Concept of a Safety-Related Sensor System for Collaboration Between Human and Automated Guided Vehicles 423
1 Introduction 423
1.1 Change in Automotive Production 423
1.2 Normative Requirements 424
1.3 Approaches to the Further Development of the Standards 425
1.4 Approaches for the Detection of People 426
2 Concept of the Safety-Related Sensor System 426
2.1 Architecture and Sensor Types 427
2.2 Experimental Setup 427
3 Conclusion and Outlook 429
References 429
Novel Autonomous Guided Vehicle System for the Use in Logistics Applications 431
1 Introduction 431
2 Mode of Operation 434
3 Logistics Application 435
4 Conclusion 437
References 438
Increased Agility by Using Autonomous AGVs in Reconfigurable Factories 440
1 Introduction 440
2 Introduction of the Research Field and its Elements 441
2.1 Automated Guided Vehicle (AGV) 441
2.2 Mobile Working Stations (MWS) 442
2.3 Real-Time Locating System (RTLS) 442
3 Research Gap 443
4 Approach of the Study 443
5 Case Study for Validation 444
6 Conclusion and Outlook 446
References 447
Safety and Operating Concept for Collaborative Material Flow Systems 448
1 Motivation and Statement of the Problem 448
1.1 Cost Factor Material Provision 448
1.2 Area of Tension Between More Efficient and Simultaneously Safer Man-Machine Collaboration 449
2 “Mobile Supermarket” Concept 450
3 Safety and Interaction Concept for the Mobile Supermarket 452
3.1 Sensor Concept 452
3.2 Man-Machine-Interaction 453
3.3 Machine-Machine-Interaction 454
4 Challenges on the Way to Flexible Production Plants with Collaborative Material Flow Systems 455
5 Conclusion 456
References 456
Combining Safe Collaborative and High-Accuracy Operations in Industrial Robots 458
1 Introduction 458
2 Basic Concept 459
2.1 Task-Oriented Path Planner and Optimization 460
2.2 Online Operation Management 460
3 Human Robot Collaboration 461
4 High-Accurate Mode 462
5 Applications 463
6 Conclusion 464
References 466
Industrial Indoor Localization: Improvement of Logistics Processes Using Location Based Services 467
1 Introduction 467
2 State of the Art 468
3 Method 469
4 Location Based Services 469
4.1 Location-Dependent Allocation Algorithm 469
4.2 Order Orchestration 471
4.3 Feature Based Recognition of Points and Areas 472
5 Conclusion 473
References 474
Interface-Free Connection of Mobile Robot Cells to Machine Tools Using a Camera System 475
1 More Complex Parts Require Flexible Automation Solutions 475
2 State of the art 476
2.1 Mobile robot cells for machine tool automation 476
2.2 Camera-based object localization and state detection 477
2.3 Goal of the work and research questions 478
3 Robust 2D object detection as enabler for flexible robot cells 478
3.1 Additional camera skills for an interface-free machine tool connection 478
3.2 Requirements for image processing and resulting conclusions 479
3.3 Marker-based machine tool localization through point clouds 479
3.4 Signal transmission through machine control panel 480
4 Experiments 481
5 Summary and outlook 483
References 483
The Fully Flexible Body Shop – A Holistic Approach for the Vehicle Production of Tomorrow 485
1 Introduction 485
2 Planning Processes 486
2.1 Definition of Requirements 486
2.2 Workspace Investigations for Flexible Clamping Technology 487
2.3 Software-supported Fixture Design 488
3 Handling and Clamping Technology 488
4 Flexible Joining 490
4.1 Laser Welding 491
4.2 Resistance Spot Welding 491
5 Discussion 491
6 Conclusion 492
References 492
Development of an Integrated Data-Driven Process to Handle Uncertainties in Multi-Variant Production and Logistics: A Survey 493
1 Introduction 494
2 Scope of Review 494
2.1 Concept of Planned Orders 494
2.2 Supply Chain Management Under Uncertainty 495
2.3 Artificial Intelligence in Multi-Variant Production 495
3 Taxonomy 496
3.1 Review Methodology 496
3.2 Classification Scheme 496
4 Review of Approaches 497
5 Discussion and Conclusion 499
References 500
Author Index 502