Florian Hoppe

Karl Mayer Stoll R&D

Bending and other manufacturing processes are subject to uncertain process conditions like varying properties of the semi-finished parts. In order to obtain precise bending angles, these variations have to be compensated. Upstream processes often deliver valuable information about the actual part properties. This paper presents a blanking-bending p...

The accuracy of metal-formed products is strongly affected by the stiffness of the machine used. Therefore, huge efforts to increase moments of inertia and reduce backlash were made in conventional press design. Multipoint servo presses allow for an alternative approach: increasing the position accuracy with respect to the press stroke direction an...

This work shows how to control the ram motion in servo-mechanical presses with non-linear kinematics by means of a model-based closed-loop control. The use of servo drives in forming machines allows for an arbitrarily controlled drive motion and paves the way for modern, more flexible and adaptable forming machines. However, servo-mechanical presse...

In engineering applications almost all processes are described with the help of models. Especially forming machines heavily rely on mathematical models for control and condition monitoring. Inaccuracies during the modeling, manufacturing and assembly of these machines induce model uncertainty which impairs the controller’s performance. In this pape...

Decision-making highly relies on the accuracy and veracity of data. Therefore, redundant data acquisition and fusion has established but lack the ability to handle conflicting data correctly. Especially digital twins, which complement physical products with mathematical models, and contribute to redundancy. Uncertainty propagates through the digita...

This chapter describes the various approaches to analyse, quantify and evaluate uncertainty along the phases of the product life cycle. It is based on the previous chapters that introduce a consistent classification of uncertainty and a holistic approach to master the uncertainty of technical systems in mechanical engineering. Here, the following t...

Uncertainty affects all phases of the product life cycle of technical systems, from design and production to their usage, even beyond the phase boundaries. Its identification, analysis and representation are discussed in the previous chapter. Based on the gained knowledge, our specific approach on mastering uncertainty can be applied. These approac...

This chapter describes three general strategies to master uncertainty in technical systems: robustness, flexibility and resilience. It builds on the previous chapters about methods to analyse and identify uncertainty and may rely on the availability of technologies for particular systems, such as active components. Robustness aims for the design of...

This chapter serves as an introduction to the main topic of this book, namely to master uncertainty in technical systems. First, the difference of our approach to previous ones is highlighted. We then discuss process chains as an important type of technical systems, in which uncertainty propagates along the chain. Five different approaches to maste...

Reliability of sensor information in today’s highly automated systems is crucial. Neglected and not quantifiable uncertainties lead to lack of knowledge which results in erroneous interpretation of sensor data. Physical redundancy is an often-used approach to reduce the impact of lack of knowledge but in many cases is infeasible and gives no absolu...

Reliability of sensor information in today's highly automated systems is crucial. Neglected and not quantifiable uncertainties lead to lack of knowledge which results in erroneous interpretation of sensor data. Physical redundancy is an often-used approach to reduce the impact of lack of knowledge but in many cases is infeasible and gives no absolu...

In this paper, the flexibility of a 3D servo-press is used as the inspiration to numerically demonstrate the ability to improve the final product, in this case reduced equivalent plastic strain, increased forming depth, and reduced punch force, during cylindrical cup-drawing. The material investigated is AA1100-O which exhibits significant anisotro...

In engineering applications almost all processes are described with the aid of models. Especially forming machines heavily rely on mathematical models for control and condition monitoring. Inaccuracies during the modeling, manufacturing and assembly of these machines induce model uncertainty which impairs the controller's performance. In this paper...

Facing the increasing amount of available data, supervision of processes is experiencing a vast upheaval. Especially time series recorded during high-speed manufacturing processes like shear-cutting challenge the interpretation of the data. This work shows how to extract features from shear cutting force data that help to explain process variations...

The stiffness of metal formed products strongly affects the dynamic behavior of structures in which they are integrated. Forming processes underlie short and long-term variations which cause the stiffness to be uncertain.In the application of resonant shunted piezoelectric transducers for vibration attenuation, uncertain stiffness may cause signifi...

In the field of autonomous systems, manufacturers still face a high level of uncertainty, especially in the development phase. These systems are characterized by their ability to adapt to new conditions without any further action by the developer. One of the future challenges will be that autonomous systems continue to evolve during the use phase....

Digitalization and Industrie 4.0 are shaping more and more industrial daily routine. As a re- sult, planning, operation and control of manufacturing processes are increasingly underta- ken by “flexible automation”. This advanced category of automation exceeds expectations in productivity under uncertain operating conditions. Coping with uncertainty...

Aufeinanderfolgende Umform- und Zerspanungsprozesse stellen im industriellen Umfeld eine typische Wertschöpfungskette dar. Die Auswirkungen von Unsicherheit werden in solchen Prozessketten bislang nur in Einzelprozessen untersucht. Gegenstand der Untersuchungen im Sonderforschungsbereich 805 ist die Entwicklung einer verketteten, geregelten Prozess...

Each process and each machine is subject to fluctuations, which lead to deviations in the quality of the components to be manufactured. In order to counter these uncertainties, a flexible incremental sheet forming (ISF) process for the production of truncated cone components is presented. These flexible methods are in contradiction with conventiona...

The increasing social demand for sustainable material use leads to new process strategies as well as to the use of new materials in nearly all industries. In light of this demand, paperboard shows potential to substitute polymer-based components while also exhibiting improved ecological properties. However, in contrast to polymer-based products, th...

Uncertainty in the properties of semi-finished parts can cause fluctuations in the product properties, especially if they have a strong effect on the process and cannot be compensated by process adjustments. Incremental forming processes have the potential to react to changing conditions by adapting the tool movement during the process. This paper...

Products of forming processes are subject to quality fluctuations due to uncertainty in semi-finished part properties as well as process conditions and environment. An approach to cope with these uncertainties is the implementation of a closed-loop control taking into account the actual product properties measured by sensors or estimated by a mathe...