Philipp Gönnheimer

The integration of both linear and circular processes in one production system poses significant challenges. In particular, the reprocessing of end-of-life products is associated with uncertainties at all levels of the production system, from the initial planning and control through to the executing production hardware and intralogistics. To addres...

Industry 4.0 has been a success story for many companies over the last ten years, not least because of the ever-growing number of profitable applications. However, the implementation of Industry 4.0 often poses a major challenge for companies, particularly in brownfield production with legacy machines, due to heterogeneous equipment and data struct...

Increasingly volatile markets, higher numbers of product variants and more sophisticated customer demands lead to a soaring complexity of productions themselves and their operations. An enabling technology that allows to cope with this increased complexity is digitization, as it enables data capturing and data driven analysis in production. Softwar...

State of the art drive controllers, based on numerical and programmable logic controllers (NC and PLC), have not yet established standardized and easily accessible endpoints to capture status and process variables, such as motor current, torque or position values. Direct access to those data sources is limited to proprietary tools or licenses and r...

Due to the ongoing trend of digitization and the strong increase in the number of Industrie 4.0 use cases, the use of machine tool process data in data-driven applications, namely process or condition monitoring, is on the rise. However, the provision of data such as motor currents or the positions of a machine’s axes—which are essential to these a...

As a result of the steadily growing importance of data-driven methods such as digital twins, approaches for automated parameter identification in production equipment are becoming increasingly important. Previous work has shown that AI-based approaches for classification are increasingly reaching their limits. As a result of new developments, CNC r...

Die wesentliche Herausforderung bei der Übertragung von Verfahren des maschinellen Lernens beruht auf dem hohen Aufwand für das erneute Antrainieren auf Zielmaschinen. Maschinengebundene Hyperparameter sowie gelabelte Daten lassen sich durch den Einsatz von Transferlernen übertragen und effizient an ausgewählten Zielmaschinen adaptieren. Nachfolgen...

When choosing an industrial robot, repeatability is often one of the most important decision factors. But repeatability is not a global property, instead, it strongly depends on the robot’s workspace position. This is currently ignored in robot cell planning leading to a loss of actual repeatability. This paper not only quantifies this loss but pre...

As new production system concepts emerge to face an increasing demand for individualized production, sensor integration for Industry 4.0 functions is becoming a major challenge. Flexibility- and scalability-focused concepts rely on reconfigurable machines that automatically replace smart end effectors between production steps. To ensure adaptabilit...

Anomaly detection is a key feature to monitor production systems an avoid downtimes, which has still not been implemented holistically. Especially in highly flexible plants or special process machines, conventional approaches like neuronal network classification or intelligent autoencoder fault detection are not suitable firstly due to the small am...

As a result of the change to Industry 4.0, the requirements for information models and digital twins are steadily increasing. Thus, reliable methods to identification and assignment of data sources in CNC machines are required. AI-based approaches are already capable of identifying individual signal groups but are increasingly reaching their limits...

One of the main advantages of additive manufacturing by Fused Filament Fabrication is its wide variety of materials and cost-effective production systems. However, the resolution and tightness of the produced structures are limited. The following article describes a novel approach of the functional integration of stereolithographic produced subcomp...

Abstract After 10 years of Industry 4.0, there is clear potential for companies, not least due to an increasing number of profitable use cases. Particularly in Brownfield Production, the initiatives usually fail due to technical requirements for data acquisition. The status quo was evaluated in the context of a survey on the fundamental importance,...

The trend towards more customized products with shorter product life cycles requires rethinking of current production systems. Due to the increasing demands for flexibility and adaptability, agile state of the art production systems come close to their limits. To improve adaptability to volatile markets, the fundamental concepts of production syste...

Since current battery cell production lines are not flexible regarding format and material, it is necessary to develop new production systems. It is also required to develop this production line as an agile system in order to be able to flexibly counteract unit-specific capacity fluctuations. In addition, only low scrap rates are allowed when integ...

Automation solutions in production represent a sensible and long-term cost-effective alternative to manual work, especially for physically strenuous or dangerous activities. However, especially for small companies, automation solutions are associated with a considerable initial complexity and a high effort in planning and implementation. The ROBOTO...

Während sich Anwendungen der künstlichen Intelligenz (KI) bereits in vielen Technologiefeldern etabliert haben und die Verfügbarkeit sowie der Support der ihnen zugrunde liegenden KI-Frameworks hoch ist, verbleiben bei der Nutzung im produktionstechnischen Bereich noch offene Potenziale. Von der initialen Entwicklung, dem nutzerorientierten Einsatz...

Der neue Mobilfunkstandard der fünften Generation (5G) bietet weitreichende Potenziale für die deutsche Wirtschaft. Insbesondere die Industrie profitiert durch den Einsatz von 5G. Prozesse können leichter digitalisiert und flexibler gestaltet werden, das Arbeiten wird mobiler und durch den Einsatz von augmentierter und virtueller Realität effizient...

In today’s highly competitive manufacturing environment, process data monitoring continues to be of high priority, but often relies on modern communication interfaces being provided by PLC manufacturers. This paper proposes an alternative approach in which data is acquired automatically from various PLC models through available interfaces. Multiple...

Digitalization and connectivity trends in industrial plants and production equipment create vast and heterogeneous networks of data sources, data sinks and various communication protocols. Data fusion and evaluation of these resources result in high costs for data integration and maintenance. Therefore, we propose a new framework, called MyGateway,...

Kürzere Produktlebenszyklen und der fortschreitende Trend zur Individualisierung von Produktionsgütern mit immer kleineren Losgrößen führen zu der Notwendigkeit eines wiederkehrenden Prozesses, der die Auswahl und Konfiguration von Produktionssystemen beinhaltet. Produktionssysteme werden dabei auf Basis der Produktanforderungen aus einer großen Za...

Industrie 4.0 ist als Trend des letzten Jahrzehnts inzwischen weltweit bekannt und steht wie kein anderer Begriff für die Innovationsfähigkeit und Kreativität von Forschung und Industrie. Dabei stellt Industrie 4.0 bisher jedoch eine im Wesentlichen digitale Innovation dar. Seitens der Hardware müssen für eine volle Ausschöpfung des Potentials die...

The increasing automation level of processes in production systems leads to new technical challenges, especially in the implementation and maintenance of software architectures. New requirements arise regarding the interface between Programmable Logic Controllers (PLC), robots, Human Machine Interfaces (HMI) and superordinate information systems (e...

One of the main advantages of additive manufacturing by Fused Filament Fabrication is its wide variety of materials and cost-effective production systems. However, the resolution and tightness of the produced structures are limited. The following article describes a novel approach of the functional integration of stereolithographic produced subcomp...

Especially in the context of Artificial Intelligence (AI) applications and increasing Overall Equipment Effectiveness (OEE) requirements, the use of data in production is gaining in importance. Applications in the field of process or condition monitoring use, for example, machine component parameters such as motor currents, travel speeds and positi...

The trend towards individualized products and the increasing demand for a greater variety of variants create new challenges for existing production environments and require a re-thinking of production. Established manufacturing systems that provide the desired flexibility are associated with significant productivity restrictions and are therefore u...

Das stetig zunehmende volatile Marktumfeld verlangt unter anderem nach hoher Effektivität der eigenen Produktion, um international wettbewerbsfähig zu bleiben. Die zur Steigerung der Anlagenverfügbarkeit beitragende Digitalisierung von Produktionsanlagen findet im Maschinen- und Anlagenbau dennoch nur zögerlich Anwendung. Auf Basis einer Unternehme...

Die stärker werdende Bedeutung von Digitalisierung im Maschinenbau stellt klein- und mittelständische Anlagenanbieter wie -betreiber vor neue Herausforderungen. Vor allem bei Bestandsanlagen in heterogenen Daten- und Schnittstellenlandschaften der Produktion sind innovative Ansätze zur Vernetzung und Erzeugung einer Datenpipeline notwendig. Ziel de...

Die industrielle Batteriezellfertigung ist geprägt durch starre Produktionssysteme für die Massenfertigung. Die Fertigung anwendungsspezifischer Zellen im geringen bis mittleren Stückzahlsegment erfolgt derzeit kostenintensiv in einer Werkstattfertigung. Basierend auf standardisierten Roboterzellen und einer flexiblen Steuerungsarchitektur wird ein...

Autonomous systems, as found in autonomous driving and highly automated production systems, require an increased reliability in order to achieve their high economic potential. Self-aware sensors are a key component in highly reliable autonomous systems. In this paper we highlight a proof of concept (PoC) of a deep learning method that enables a LiD...

Bereits heute existieren vereinzelt vielversprechende industrielle Anwendungen der Künstlichen Intelligenz, vor allem in den Bereichen Prozess- und Zustandsüberwachung. Heutige KI-Modelle werden jedoch ausschließlich als Insellösungen für einen Prozess und eine Maschine entwickelt. Durch heterogene Produktionsanlagen existieren kaum prozess- und zu...

The digitalisation of production technology is becoming increasingly important today and will play a key role in machine tools in the future. In order to generate as much information as possible about machines and components as well as the product, the number of sensor systems and further devices is constantly increasing. A challenge with this incr...

In machine tools, Industry 4.0 functions can increase availability through predictive maintenance, while other functions improve productivity and workpiece quality through process supervision and optimisation. Many of these functions rely on data communication between systems from different suppliers. Requirements regarding latency and computing va...

Shorter product lifecycles lead not only to faster time-to-market for products but also to the need for just as fast available associated production systems. These shorter product lifecycles, as well as the increasing individualization of products, also result in further decreasing production lot sizes. Young companies in China in particular are ch...

Shorter product lifecycles and increasing individualization of products lead to the necessity for a reoccurring process, which includes the selection and configuration of production systems to provide a system that produces the product. Especially in fast developing countries like China, the offer for this knowledge can hardly supply the demand. In...

Access to data from components in production systems is potentially an enabler for various data-based approaches. This paper presents a practical approach to transform mechanical components into self-describing cyber-physical systems connected within a local network. The requirements for typical use cases are analysed and a modular cyber-physical c...

The development and production of electric drives as mechatronic products involve several engineering domains. With increasing complexity of the individual parts, frequently shifting customer requirements and ever shorter development cycles, integrated approaches are continuing to grow in importance. In this context, an interdisciplinary design met...