SFB 653: Gentelligent Components in their Lifecycle - Utilisation of Inheritable Component Inherent Information in Production Engineering
Final Report Abstract
The production of the future has to fulfil high requirements: it needs to be adaptive and it has to enable production of individual products with a batch size of one. It has to be intelligent, efficient and sustainable. This view into the future shows factories in which components and machines communicate with one another and make independent decisions - they are active, independent components of connected production systems. The Collaborative Research Centre 653 "Gentelligent components in their lifecycle – Utilization of inheritable component information in product engineering" creates the basis for this future and goes a step beyond the conventional technologies of data chips. The vision consists of the physical integration of the component with its reproduction and stress information from the life cycle. The long-term research objective is the abolition of this separation of component and related information by developing gentelligent components, which are equipped with genetic and intelligent properties. The intended inherent information gathering and storage makes an important contribution to the further development of production technology and product development for the use in production systems of the future. The leading questions for the realization of this objective were also the basis for the structure of the SFB, which was divided into five project areas. The scientific research program is oriented towards the three funding periods and follows the "Fundamentals - Development - Integration" approach. In the first four years, it has been experimentally and simulatively demonstrated that components for inherent load sensing and storage can be enabled and first gentelligent prototypes were developed. The findings have been used to develop maintenance, planning and machine tool systems that have significant advantages in terms of accuracy, flexibility, and data consistency compared to conventional systems. To this end, the production technologies and approaches were developed and the basic knowledge required in material knowledge, micro production and production technology as well as signal transmission and analysis was established. The aim of the second funding period was the further development of the functional properties of the gentelligent components for gentelligent systems with advanced technology and application spectrum. The storage densities and load sensitivities of the gentelligent components could be significantly increased. Through the further development of the magnetic magnesium alloys reproducible loadings have been achieved. The developed micro structuring of the component surfaces in machining processes enables a reliable component identification. Moreover, the further miniaturization of the components for component-inherent communication was realized. In the project area S, the technologies for integrity assessment were further developed and their application flexibility expanded. By developing a load-sensitive tool carriage, a further source of information for process monitoring and evaluation could be created. In addition, the added value of gentelligent components was demonstrated by a new component-based maintenance approach. The process for the production of inherent energy and signal transmissions has been further developed and state-based information from gentelligent components has been used in new approaches for process simulation and production control. The main objective of the third funding period was the integration of the approaches into the application framework of a gentelligent production as well as the development of implementation strategies with the focus on the transfer of knowledge of developed individual technologies and systems into the practical application through transfer projects. In order to achieve this and at the same time to demonstrate more clearly the potential for industrial use in future production systems, a "Gentelligent Production" was established for the first time in the third funding period. For this purpose, the technologies of the subprojects were integrated into the closed circuit of high-end components with the phases of product creation, production, use and information retrieval. In the individual project areas, further developments for the signal analysis and transmission, storage capacity and studies on possibilities of transferability as well as increase of the performance were realized. This integration of the approaches in a gentelligent production carried out by the end of the third period created the basis for the transfer of basic research into the industrial application and thus to the sustained increase of the competitiveness of the production technology in Germany.
Publications
- Verfahren zur Herstellung eines Gussteils, DE102007062436, 20.12.2007
Kerber, K., Bach, F.-W.; Schaper, M.
- Acquisition of discrete component and loading information in the component’s edge region using innovative sensor technology, 4th I*PROMS 2008 Virtual International Conference on Innovative Production Machines and Systems, S. 431-437, 2008
Mroz, G., Reimche, W., Bach, F.W.
- Verfahren zur Herstellung von Presslingen, DE102008035854, 01.08.2008
Lange, F., Behrens, B.-A., Gastan, E.
- Bauteil, Verfahren zum Einbringen von Informationen in ein Bauteil und Verfahren zum Ermitteln einer Belastungshistorie eines Bauteils, DE102009056584, 01.12.2009
Reimche, W., Mroz, G., Bach, Fr.-W.
- Verfahren zum Erkennen von Rattern, Werkzeugmaschinen-Überwachungsvorrichtung und Werkzeugmaschine, DE102010019419, 04.05.2010
Denkena, B., Möhring, H.-C.; Litwinski, K., Hackelöer, F.
- Ablösbare Mikro- und Nanobauteile für platzsparenden Einsatz, DE102011004782, 25.02.2011
Gatzen, H.-H., Griesbach, T.
- Experimental and Numerical Investigation on Manufacturing Methods of PM Components with Integrated Information Storage, Journal of Advanced Manufacturing Systems, Vol. 10, No. 1, S. 11-20, 2011
Behrens, B.-A., Vahed, N., Gastan, E., Lange, F.
(See online at https://doi.org/10.1142/s0219686711001928) - Struktureinrichtung mit einem Bauelement, Vorrichtung zur Applikation des Bauelements, Verfahren zur Herstellung der Struktureinrichtung und Verfahren zur Applikation des Bauelements, DE102011108981, 01.08.2011
Rissing, L., Griesbach, T.
- Adaptive process planning, Production Engineering, Vol. 6, Nr. 1, 2012
Denkena, B., Lorenzen, L.-E., Schmidt, J.
(See online at https://doi.org/10.1007/s11740-011-0353-7) - Laser patterning of thin film sensors on 3-D surfaces, CIRP Annals, Vol. 61, Nr. 1, S. 215-218, 2012
Overmeyer, L., Düsing, J.F., Suttmann, S., Stute, U.
(See online at https://doi.org/10.1016/j.cirp.2012.03.087) - Magnetic Magnesium Alloys Based on MgZn and SmCo with Sensory Properties, Advanced Engineering Materials, Vol. 14, Nr. 1-2, S. 28-34, 2012
Klose, C., Mroz, G., Rodman, M., Kujat, B., Bormann, D., Reimche, W., Bach, Fr.-W.
(See online at https://doi.org/10.1002/adem.201100197) - Planfräsverfahren und Planfräskopf sowie Bauteil und Fräsvorrichtung, DE 102012002140, 27.01.2012
Denkena, B., Gümmer, O., Köhler, J., Litwinski, K., Möhring, H-C., Mörke, T.
- Teachless Process Monitoring for Single Part Production, 1st Joint International Symposium on System-Integrated Intelligence 2012: New Challenges for Product and Production Engineering, 27.-29.06.2012, S. 117-119, 2012
Denkena, B., Köller, M., Bertram, O.
- A model-based approach for monitoring of shape deviations in peripheral milling, International Journal of Advanced Manufacturing Technology, Vol. 67, Nr. 9, S. 2537-2550, 2013
Denkena, B., Krüger, M.
(See online at https://doi.org/10.1007/s00170-012-4672-4) - Design Evolution by Integration of Life Cycle Information in Knowledge Repositories, Consilience and Innovation in Design, 5th International Congress of International Association of Societies of Design Research, Tokyo, Japan, 2013
Lachmayer, R., Mozgova, I., Deiters, A., Sauthoff, B., Gottwald, P.
- Influence of Cobalt on the Properties of Load-Sensitive Magnesium Alloys, Sensors , Vol. 13, Nr. 1, S. 106-118, 2013
Klose, C., Demminger, C., Mroz, G., Reimche, W., Bach, Fr.-W., Maier, H. J., Kerber, K.
(See online at https://doi.org/10.3390/s130100106) - Development and first applications of gentelligent components over their lifecycle, CIRP Journal of Manufacturing Science and Technology, Vol. 7, Nr. 2, S. 139-150, 2014
Denkena, B., Mörke, T., Krüger, M., Schmidt, J., Boujnah, H., Meyer, J., Gottwald, P., Spitschan, B., Winkens, M.
(See online at https://doi.org/10.1016/j.cirpj.2013.12.006) - In-Line Production, Optronic Assembly and Packaging of POFs, Procedia Technology, Vol. 15, S. 129-137, 2014
Hachicha, B., Overmeyer, L.
(See online at https://doi.org/10.1016/j.protcy.2014.09.064) - Investigations on strain behaviour of polymer substrates during a separation process, Procedia Technology, Vol. 15, S. 221-229, 2014
Jogschies, L., Heitmann, J., Klaas D., Rissing, L.
(See online at https://doi.org/10.1016/j.protcy.2014.09.075) - Laser surface processing of integrated thin film systems, Procedia Technology, Vol. 15, S. 122-128, 2014
Düsing, J.F., Eichele, T., Koch, J., Overmeyer, L.
(See online at https://doi.org/10.1016/j.protcy.2014.09.063) - Simulation based Process Monitoring for Single Item Production without Machine External Sensors, Procedia Technology, Vol. 15, S. 341-348, 2014
Denkena, B., Fischer, R., Euhus, D., Neff, T.
(See online at https://doi.org/10.1016/j.protcy.2014.09.088) - Design and investigation of meshed patch antennas for applications at 24 GHz, European Microwave Conference 2015, Paris, France, 2015
Dao, Q.H., Braun, R., Geck, B.
(See online at https://doi.org/10.1109/EuRAD.2015.7346341) - Determining a Suitable Maintenance Measure for Gentelligent Components Using Case-based Reasoning, International Journal of Mechanical, Aerospace, Industrial and Mechatronics Engineering Vol. 9, Nr. 1, Riverside, CT, USA, S. 257-260, 2015
Winkens, M.; Nyhuis, P.
(See online at https://doi.org/10.5281/zenodo.1337763) - Flexibles magnetisches Lese-/ Schreibsystem: Design eines Schreibkopfes, VDI-Gesellschaft Mikroelektronik, Mikrosystem- und Feinwerktechnik (Ed.), MikroSystemTechnik Kongress 2015, MEMS, Mikroelektronik, Systeme 26.-28.10.2015, Karlsruhe, VDE Verlag, Berlin, S. 684-688, 2015
Taptimthong, P., Rittinger, J., Wurz, M.C., Rissing, L.
- Formulation of Paradigm of Technical Inheritance, Proceedings of the 20th International Conference on Engineering Design (ICED15), Mailand, Italien, 27.- 30.07.2015, S. 271-278, 2015
Lachmayer, R., Mozgova, I., Gottwald, P.
- Recent developments of magnetoresistive sensors for industrial applications, Sensors, Vol. 15, Nr. 11, S. 28665-28689, 2015
Jogschies, L., Klaas, D., Kruppe, R., Rittinger, J., Taptimthong, P., Wienecke, A., Rissing, L., Wurz, M.C.
(See online at https://doi.org/10.3390/s151128665) - Use of Life Cycle Data for Condition-Oriented Maintenance, International Journal of Mechanical, Aerospace, Industrial and Mechatronics Engineering, Vol. 9, Nr. 4, S. 1178-1181, 2015
Winkens, M.; Goerke; M.; Nyhuis, P.
(See online at https://doi.org/10.5281/zenodo.1100382) - An optically transparent analog frontend for a solar powered 24 GHz RFID transponder, International Microwave Symposium (IMS 2016), San Francisco, California, USA, 2016
Dao, Q.H., Lüers, B., Ngo, T., Geck, B.
(See online at https://doi.org/10.1109/MWSYM.2016.7539991) - Closed-loop process control for laser patterning of thin film strain sensors, Procedia Technology, Vol. 26, S. 113-119, 2016
Düsing, J.F., Koch, J., Suttmann O., Overmeyer, L.
(See online at https://doi.org/10.1016/j.protcy.2016.08.016) - Detection of tool deflection in milling by a sensory axis slide for machine tools, Mechatronics Vol. 34, S. 95-99, 2016
Denkena, B., Litwinski, K., Boujnah, H.
(See online at https://doi.org/10.1016/j.mechatronics.2015.09.008) - Development of a humidity sensor element based on sputterdeposited thin ZnO-layers, Procedia Technology, Vol. 26, S. 27-34, 2016
Klaas, D., Rein, M., Wurz, M.C., Rissing, L.
(See online at https://doi.org/10.1016/j.protcy.2016.08.005) - Enabling of component identification by high speed measuring of grinding wheel topography, Procedia Technology, Vol. 26, S. 252-258, 2016
Breidenstein, B., Denkena, B., Grove, T., Hockauf, R.
(See online at https://doi.org/10.1016/j.protcy.2016.08.034) - Flexible magnetic reading/writing system: heatassisted magnetic recording, Procedia Technology, Vol. 26, S. 72-78, 2016
Taptimthong, P., Düsing, J.F., Rissing, L., Wurz, M.C.
(See online at https://doi.org/10.1016/j.protcy.2016.08.011) - Functionalization of UV-curing adhesives for surface-integrated micropolymer optical fibers, SPIE: Photonic West. Integrated Optics: Devices, Materials, and Technologies, San Francisco, California, USA, 3.-18.02.2016, Vol. 9750, Nr. 17, 2016
Hachicha, B., Overmeyer, L.
(See online at https://doi.org/10.1117/12.2212772) - New coating system for direct-deposition of sensors on components of arbitrary size, IEEE SENSORS 2016, 30.10.-2.11.2016, Orlando, Florida, USA, 2016
Klaas, D., Becker, J., Wurz, M.C., Schlosser J., Kunze, M.
(See online at https://doi.org/10.1109/ICSENS.2016.7808440) - Production Monitoring based on Sensing Clamping Elements, Procedia Technology, Vol. 26, 2016, S. 235-244, 2016
Denkena, B., Dahlmann, D., Kiesner, J.
(See online at https://doi.org/10.1016/j.protcy.2016.08.032) - Strain gauge based sensing hydraulic fixtures, Mechatronics, Vol. 34, S. 111- 118, 2016
Denkena, B., Kiesner, J.
(See online at https://doi.org/10.1016/j.mechatronics.2015.05.008) - Wellenleiteranordnung zur Übertragung elektromagnetischer Wellen mit einem Hohlleiter und einem im Hohlleiter angeordneten planaren Leiter, DE102006053389, 10.11.2006
Kaldjob, E. B., Gamal El Din, M.
- Assessment of mechanical loads based on surface integrity analysis of machined components, CIRP Annals, Vol. 66, Nr. 1, S. 85-89, 2017
Grove, T., Mörke, T.
(See online at https://doi.org/10.1016/j.cirp.2017.04.030) - Cyber-Physical and Gentelligent Systems in Manufacturing and Life Cycle, 1. Ausgabe, Elsevier Fachverlag, 2017
Denkena, B. Mörke T. (Hrsg.)
- Das gentelligente Werkstück, Handbuch Industrie 4.0 - Geschäftsmodelle, Prozesse, Technik, 1. Ausgabe, Hanser Verlag, S. 295-321, 2017
Denkena, B., Dittrich, M.-A., Uhlich, F., Maibaum, L., Mörke, T.
(See online at https://doi.org/10.3139/9783446449893.012) - Technical inheritance: Information basis for the identification and development of product generations. DS 87-6 Proceedings of the 21st International Conference on Engineering Design (ICED 17), Vol 6: Design Information and Knowledge, S. 91-100, Vancouver, Canada, 21.-25.08.2017
Mozgova, I., Barton, S., Demminger, C., Miebach, T., Taptimthong, P., Lachmayer, R, Nyhuis, P., Reimche, W., Wurz, M.C.
- Tempering control of forging processes by integration of cavities, Cyber-Physical and Gentelligent Systems in Manufacturing and Life Cycle, 1. Ausgabe, Elsevier Fachverlag, S. 378-398, 2017
Behrens, B.-A., Bonhage, M., Malik, I. Y., Bonk, C.
- Tool deflection control by a sensory spindle slide for milling machine tools, 10th CIRP Conference on Intelligent Computation in Manufacturing Engineering - CIRP ICME '16, Procedia CIRP, Vol. 62 S. 329-334, 2017
Denkena, B., Dahlmann, D., Boujnah, H.
(See online at https://doi.org/10.1016/j.procir.2016.06.059)
