Jochen Bönig

• Dr.-Ing.
• Head of Department at Siemens

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....

Due to customer specific products, the number of product variants and the complexity of assembly processes increase. To meet these challenges, worker information systems are used to manage information diversity in manual assembly and to provide the right information at the right time in a lean way. Such systems are available in various types and th...

A continuously rising number of electric vehicle licensing is mentioned since the last few years in Germany. For a cost-efficient production of electrical engines in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby, the prediction of wire behavior is one of the key challenges. Th...

The supply of defect-free, high-quality products is an important success factor for the long-term competitiveness of manufacturing companies. Despite the increasing challenges of rising product variety and complexity and the necessity of economic manufacturing, a comprehensive and reliable quality inspection is often indispensable. In consequence,...

A computer-implemented method of predicting a quality of a printed circuit board (PCB) assembly includes obtaining production data relating to production of the PCB assembly. The production data is mapped onto a latent vector of a latent space of a trained adaptive algorithm. The trained adaptive algorithm is trained on real X-ray images of PCB ass...

A computer-implemented method of automated X-ray inspection during the production of printed circuit board, PCB, assemblies. The method includes capturing an X-ray image of a PCB assembly, determining a first error indicator based on image processing of the captured X-ray image, determining, in case the first error indicator indicates the PCB assem...

The success factors of modern, global competition are changing the framework conditions of industrial production in a sustainable way. The optimization of the manufacturing process of electronic assemblies must ensure that they meet the requirements for adapted strategies and new design concepts, in particular in the field of digitization. Due to t...

Kurzfassung In diesem Beitrag wird ein Konzept zur dynamischen Röntgenprüfung in der Elektronikproduktion vorgestellt, das durch die Auswertung von Prozessdaten mithilfe von Data-Mining-Verfahren die Prognose der finalen Produktqualität im laufenden Prozess erlaubt. Dies ermöglicht die Reduzierung von Röntgenprüfumfängen durch die Entwicklung dynam...

Human-robot collaboration (HRC) has the potential to increase the degree of automation, and thus productivity, throughout many industries. However, complex safety considerations and a lack of appropriate planning tools still prohibit a more widespread application. In this paper, the use of virtual commissioning (VC), an established tool for the val...

In this paper the influence of the Villari effect, also known as the magnetoelastic effect due to the shrink fitting of rotor cores, on the magnetizing current of electrical machines is investigated. Typically the assembly between the shaft and the rotor lamination stack is done by an interference fit. The resulting mechanical tensions in the rotor...

Die Entwicklung und der Einsatz digitaler Methoden zur durchgängigen virtuellen Absicherung ist eine entscheidende Voraussetzung für den Erhalt der Wettbewerbsfähigkeit in einem zunehmend globalisierten Marktumfeld. Neben rigiden Bauteilen befinden sich in mechatronischen Systemen auch flexible Komponenten, die ebenfalls anhand digitaler Methoden b...

Due to rapid developments in technology, the complexity of assembly processes has increased. To meet these challenges, effectively qualified workers are necessary. A worker must have a basic education to understand new training content and be able to translate it into daily work. Also, a fast and efficient data flow from innovations within product...

Through customers’ desire for an individualization of vehicles, new electronics-supported functions are continuously being added. The automobile wiring harness must meet these requests without any further increase of weight and volume. The basic trend towards a modular vehicular design, the continually growing complexity of production and assembly...

There are a lot of different kinds of electric drives and each category has a different installation position within a vehicle. A huge number of variants pose a challenge for manual assembly as the varying constellations of high-voltage (HV) cables require individual assembly steps. A worker needs information both about a vehicle and about HV compo...

Due to fast technological developments and customer specific products, the number of product variants and the complexity of assembly processes increase. To meet these challenges, an effective worker qualification for new tasks is necessary. We identified two prerequisites for worker qualification. A worker must have a basic education concerning his...

Slowly but steadily, more and more electric vehicles push onto the consumer market. For a cost efficient production of electrical engines, in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby the prediction of the wire behavior is one of the key challenges. Therefore, a detailed m...

Slowly but steadily, more and more electrical vehicles push onto the consumer market. To produce electrical engines cost efficient, in first-class quality and in sufficient quantity, it is indispensable to understand the process of winding. The prediction of the wire behaviour is one of the key challenges of coil winding. Therefore, a detailed mode...

Die Globalisierung wirkt sich auf Unternehmen nicht nur im Bereich der Verarbeitung und des Transports materieller Güter aus, sondern auch auf die assoziierten Datenflüsse. Die weltweit verteilte Erstellung und Bearbeitung von Daten stellt erhöhte Anforderungen an die Zusammenführung und lokale Nutzung. Insbesondere Produktentwicklungsdaten sollen...

A key challenge in production engineering projects is to achieve significant time and cost savings through early validation of manual assembly operations. Nevertheless, the use of digital human models for dynamic analyses is not very prevalent because of the high modeling complexity in the digital environment: with existing simulation tools, the wo...

Using a digital human model for dynamic analysis is due to the high modelling complexity in digital environments not very prevalent. The movement of the worker is either unrealistic, or time-consuming to realize. Therefore, the need for research is a time saving possibility to explore virtual validation by a human model taking advantage of a noneth...

Globalization does not only affect enterprises in areas such as processing and transportation of material goods, but also with a view to the associated data flows. Distributed data generation and processing places higher demands on data fusion and local use. Especially product development data have to be made available for production planning and e...

The use of electric power systems in automobiles represents a massive change in the production line of car manufacturers. To guarantee an efficient and at the same time damage free installation of the current carrying high-voltage cables, virtual validation of assembly operations makes an important contribution. On the market available simulation t...

Driven by the demand for green mobility alternatives and the claim to reduce the carbon footprint, technologies for electric mobility are on the advance. Although the idea of using electricity as drive energy came up more than 150 years ago, a considerable potential of development still remains. The automotive industry is in the midst of a time of...

Virtual Manual Assembly Validation

The future competitive situation in the automotive industry and the increasing market demands will inevitably lead to higher complexity in product development, production planning and pre-series. Longer lifecycles of assembly systems based on highly flexible production cells with a rising number of integrated processes call for new challenges, espe...

Die Produktion elektrifizierter Fahrzeuge sowie deren Komponenten und insbesondere des Energiespeichers unterscheidet sich grundlegend von den Produktionsprozessen für Fahr¬zeuge mit Verbrennungsmotor. Das Ziel des Projektes eProduction ist die Forschung und Entwicklung für eine sichere, robuste und nachhaltige Produktion elektrischer Fahrzeuge. Di...