Advances in Automotive Production Technology – Towards Software-Defined Manufacturing and Resilient Supply Chains: Stuttgart Conference on Automotive Production (SCAP2022)

Description

This volume of the series ARENA2036 compiles the outcome of the 2nd Stuttgart Conference on Automotive Production (SCAP2022).  The peer-reviewed contributions in this book are arranged thematically in three parts and cover a wide variety of topics: (A) Software-defined Manufacturing, (B) Data-driven Technologies, and (C) Advanced Manufacturing and Sustainability. SCAP2022 was organized by ARENA2036 in close collaboration with the Institute for Control Engineering of Machine Tools and Manufacturing Units of the University of Stuttgart. The Conference took place on site from November 16 - 18, 2022 and provided the opportunity for national and international scientists to present their latest research results.    The conference has taken another big step in becoming an established forum for topics related to the production of the future. The great success of this year's conference will be continued with the next SCAP in 2024 with new forward-looking topics.  This is an open access book. Editorial Contents Part A: Software-Defined Manufacturing Real-Time Capable Architecture for Software-Defined Manufacturing 1 Introduction 1.1 Limitations of State of the Art Manufacturing Systems 1.2 Software-Defined Manufacturing as a New Paradigm 2 Requirements Analysis Based on Related Work 2.1 Requirements from the Automation Application Life Cycle 2.2 Requirements Based on Published Approaches to SDM 3 Architecture Proposal 3.1 Integration in a Conceptual SDM Framework 3.2 Virtualization and Orchestration 3.3 Network and Application Configuration 4 Conclusion and Future Work References Analysis of Real-Time Execution Models for Container-Based Control Applications 1 Introduction 2 Related Work 3 Analysis of Scheduling Methods 4 Execution Models for the Container-Based PLC 4.1 Cyclic Execution Model 4.2 Event-Based Execution Model 5 Validation of a Sample Use-Case 6 Conclusion and Future Work References Software-Defined Manufacturing for the Entire Life Cycle at Different Levels of Production 1 Introduction 2 State of the Art 3 Approach 3.1 Machine 3.2 Production System 3.3 Production Network 4 Exemplary Use Case 5 Discussion and Conclusion References Dynamic Safety Distance Determination for Human Robot Coexistence in Industrial Applications*-12pt 1 Introduction 2 Related Work 3 Accurate Speed and Separation Monitoring 3.1 Calculation According to the Norm 3.2 Human and Robot Modeling 3.3 Implementation Details and Monitoring Differences 4 Simulation 4.1 Scenario 4.2 Implementation Details 4.3 Evaluation 5 Requirements and Safety Discussion 6 Conclusion and Future Prospects References Integrated Framework for Safety Management and Software-Assisted Safety Assessment in Fluid Production*-12pt 1 Introduction 2 Related Work 3 Modeling and Integrated Process for the System Commissioning 4 Fluid Production Safety 4A-Framework (FluPro-S4A) 4.1 Step 1: Change Acknowledgement 4.2 Step 2: Asset Assessment 4.3 Step 3: System Assessment 4.4 Step 4: Approval Assistance 5 Case Study 6 Conclusion and Future Work References Part B: Data-Driven Technologies Improvement of the Scheduling of Automotive Testing Processes Based on Production Scheduling Methods 1 Introduction 2 State of the Art 3 Test Field Modelling 3.1 Physical Test Field 3.2 Virtual Test Field 4 Scheduling Results 5 Conclusion and Outlook References Mixed-Integer Programming Model for Scheduling of Modular Automotive Body-In-White Production Systems*-12pt 1 Introduction 2 State of the Art 3 Proposed Mixed-Integer Programming Model 3.1 Notations 3.2 Model 4 Results and Discussion 5 Conclusion References Robotic Assembly Line Balancing with Multimodal Stochastic Processing Times*-12pt 1 Introduction 2 State of Research 3 Objective 4 Genetic Algorithm 4.1 Solution Representation 4.2 Steps of the GA 4.3 Decoding Procedure for the RALBP 5 Results 6 Conclusion and Future Research References Elementary Welding Operations for Automatic Robot Programming 1 Introduction 2 Related Work 3 Elementary Welding Operation 4 Technical Implementation 5 Experiments and Results 6 Discussion and Conclusion References Influence of the Joining Force on the Nugget Diameter During Resistance Spot Welding of Aluminum Materials 1 Introduction 2 Hypothesis and Method 3 Literature Review 4 Setup 4.1 Material 4.2 Equipment and Execution 4.3 Meta Data and Design of Experiments 5 Target Data and Feature Engineering 5.1 Target Data 5.2 Feature Engineering 6 Results 6.1 Machine Learning Approaches 6.2 Permutation Feature Importance 6.3 Visualization of Datasets 6.4 Second Degree Regression 7 Conclusion and Outlook References Towards an Automated System for Robot Assembly Cell Layout Optimization 1 Introduction 2 Aspects of Automated Layout Optimization 2.1 Definition of Criteria for 3D Simulation Generation and Optimization 3 Approaches for 3D Modelling and Optimization 4 State of the Art Discussion 5 Concept Formulation 6 Conclusion and Next Steps References Adaptive Intralogistics with Low-Cost AGVs for a Modular Production System*-12pt 1 Introduction 2 Current Situation 3 Novel Platform for Modular Production 4 Scalable Low-Cost AGV Construction Kit 5 Communication Using Dynamic LED Tracks 6 Conclusion References Topology Planning in Swarm Production System: Framework and Optimization 1 Introduction 2 State of the Art 2.1 FLP in Changeable Manufacturing 2.2 Optimization Methods in FLP 2.3 Optimization with Graph Theory 2.4 Optimal Approach in Topology Manager(TM) 3 Topology Manager Framework 4 Exemplification 4.1 Batch Processing Module 4.2 Topology Estimation and Optimization Module 4.3 Reconfiguration Decision Module 5 Experimental Results 6 Discussion and Conclusion References Using Meta-Learning to Reduce the Effort of Training New Workpiece Geometries for Entanglement Detection in Bin-Picking Applications*-12pt 1 Introduction 2 Meta-Learning 3 Meta-Learning Applied to the Entanglement Detection 3.1 Base Dataset 3.2 Implementation to the Entanglement Detection 3.3 Training of the Meta-Learning Methods 4 Results 4.1 Comparison of Applied Meta-Learning Methods 4.2 Performance Validation of the Meta-trained Entanglement Detection on Unseen Workpiece Geometries 5 Summary and Outlook References Performance Comparison of Supervised and Reinforcement Learning Approaches for Separating Entanglements in a Bin-Picking Application*-12pt 1 Introduction 2 State of the Art 3 New Supervised Learning Entanglement Separation Method 3.1 Data Generation 3.2 Network Architecture 3.3 Training 3.4 Threshold Evaluation 4 Comparison 4.1 Setup Effort 4.2 Real-World Performance Comparison 4.3 Integration into a Bin Picking System 5 Conclusion and Future Work References Machine Learning-Based Identification of Root Causes for Defective Units in Manufacturing Processes 1 Introduction 2 Theoretical Background 2.1 Classical Methods 2.2 Method Based on Attention Mechanism 3 Data 4 Results 5 Discussion 6 Conclusion References Enabling Single-Sensor Simultaneous Condition Monitoring of Several Vibration-Emitting Machine Parts Using Neural Networks 1 Introduction 2 Theoretical Background and Methods 2.1 Convolutional Neural Network 2.2 Discrete Fourier Transform 2.3 Methods 3 Experimental Setup 4 Results 4.1 Data Transformation 4.2 Training and Evaluation 4.3 Discussion 5 Conclusion References Unlocking the Potential of Digital Twins 1 Introduction 2 State of the Art 2.1 Life Cycle of Production Plants 2.2 Digitalisation of the Planning, Realization and Operation Phases 3 Concept, Industrial Use Case and Challenges 3.1 Use Cases for Digital Twins 3.2 Development of the Virtual Commissioning Model Towards a Digital Twin 3.3 Example of an Industrial Use Case 3.4 Challenges 4 Conclusion and Outlook 4.1 Conclusion 4.2 Outlook References Hybrid Digital Twins Using FMUs to Increase the Validity and Domain of Virtual Commissioning Simulations 1 Introduction 2 State of the Art in Virtual Commissioning Simulations with Increased Level of Detail 3 Methods and Concept of Hybrid Digital Twins 4 Validation Use Case Inverted Pendulum 4.1 Modeling and Simulation Setup 4.2 Simulation Results and Interpretation 5 Conclusion and Outlook References Towards the Smart Factory: Process Optimization in Virtual Commissioning 1 Introduction 2 State of the Art 2.1 Conventional Planning 2.2 Digital Factory and Twin 3 Process Analysis 3.1 Metrics 3.2 Problem Analysis 3.3 Problem Solutions 4 Process Optimization 4.1 Process Integration 4.2 Educating and Training Employees 4.3 Technical Changes 4.4 Use Cases 5 Conclusion and Outlook References A New IT Architecture for the Digital Factory 1 Introduction 1.1 Digital Factory 1.2 Data Model PPR – Product, Process, Resource 1.3 Scope 1.4 Main Requirements 1.5 State of the Art 2 System Design 2.1 General Approach 2.2 Interface Design 2.3 Example Application 3 Outlook 4 Conclusion References Security Analysis of a Blockchain Based Data Collection Method for Cross Company Information Sharing 1 Introduction 2 Related Work 2.1 Cross Company Data Exchange 2.2 Threat Modelling for Production 3 Proposed Solution Architecture 4 System Analysis 5 Findings 5.1 Infrastructure 5.2 Employee 5.3 Business 6 Summary References Part C: Advanced Manufacturing and Sustainability Combination of the Scanning and the Polar Measuring Method for the Defect Detection in Dry Fibre Layups Using an Eddy Current Sensor 1 Introduction 2 Literature Review 2.1 Carbon Composite Manufacturing 2.2 Eddy Current Sensors 2.3 Measuring Methods 3 Method 3.1 Hardware Selection 3.2 Specimen and Experimental Plan 4 Results and Discussion 4.1 Fibre Orientation 4.2 Gap Detection 4.3 Foreign Objects 4.4 Discussion 5 Conclusion References Detection of Gaps and Overlaps in Laser Line Triangulation Data of Dry Fibre Tape Layups Using Image Projection 1 Introduction 1.1 Background 1.2 Dry Fibre Tape Placement 1.3 Defects and Irregularities 1.4 Laser Line Triangulation 1.5 In-Line Implementation 2 Literature and Methods 2.1 Evaluation Methods in the Literature 2.2 Research Method for the Algorithm Assessment 2.3 Specimen, Hardware and Preprocessing 3 Results 3.1 Image Projection 3.2 Adaptive and Cell-Wise Thresholding 4 Discussion 5 Conclusion and Outlook References Parameter Study and Optimization of Forming Simulations for Tape-Based Fiber Layups 1 Introduction 2 State of the Art 3 Methodology 3.1 Initial Finite Element Model 3.2 Parametrization Setup 3.3 Analysis 4 Results 5 Discussion 6 Conclusion and Outlook References Analysis of New Concepts for the Consolidation Roller in Laser-Assisted Automated Tape Placement Processes 1 Introduction 1.1 Thermoplastic In-Situ AFP 1.2 Compaction Roller Overview 2 Methodology 2.1 Analytical Analysis of Compaction Roller Contact and Deformation 2.2 Compaction Rollers Fabrication and Experimental Test Setup 2.3 Simulation Setup 3 Results and Discussion 3.1 Experimental Results: Pressure Uniformity 3.2 Experimental Results: Compaction Pressure 3.3 Simulation 4 Conclusion References Development, Implementation and Evaluation of a Prototype System for Data-Driven Optimization of a Preforming Process 1 Introduction 1.1 Forming of Woven Fabrics 1.2 Sensors for Composite Structures and Manufacturing 1.3 Strain Sensing 1.4 Edge Computing 2 Experimentation 2.1 Basic Materials 2.2 Sensor Characterization 2.3 Strain Sensor System 2.4 Integration into Edge Device 2.5 Draping Process 3 Results 4 Conclusion References Resource Efficient Manufacturing of Complex Cooling Structures 1 Motivation 2 State of the Art 3 Proposed Advantages Through the Enhancing of Injection Molded Encapsulations with Additive-Built Inserts 4 Motivation in the HEaK Project 4.1 Design of the Insert Structure 5 Preliminary Investigations 5.1 Pressure Tests 5.2 Powder Investigations 6 Conclusion References The Potential of High Speed Sintering for Small Series in the Automotive Industry 1 Introduction 2 Rapid Manufacturing vs. Rapid Prototyping 3 Introduction to High Speed Sintering 4 Research Approach 5 Development of Design Guidelines for HSS 6 Use of HSS for the Manufacturing of a Speaker Cover 7 Conclusion 8 Limitations and Further Research References Asset Administration Shell for the Wiring Harness System 1 Introduction 2 Changing the Value Chains for Wiring Harness 2.1 Wiring Harness in Current Value Chains 2.2 Vision – Uniform Data Representation Along the Complete Life Cycle 2.3 The Asset Administration Shell 2.4 Potentials by Using Digital Twins 3 Asset Administration Shell for the Wiring Harness (VWS4LS) 4 Status of Development 5 Conclusion and Further Development References Case Study on Localization for Robotic Wire Harness Installation 1 Introduction 2 Problem Statement 3 Related Works 4 Contribution 5 Concept 5.1 Wire Harness Localization 5.2 Component Localization 6 Evaluation 6.1 Experimental Setup 6.2 Evaluation of Wire Harness Localization 6.3 Evaluation of Component Localization 7 Conclusion References Traceability in Battery Production: Cell-Specific Marker-Free Identification of Electrode Segments 1 Introduction 1.1 Traceability in Lithium-ion Battery Production 1.2 Identification Techniques 2 Cell-Specific Identification of Electrode Segments 2.1 Marker-Free Identification Using Surface Microstructures 2.2 Approach for Proving Concept Implementation 3 Conclusion and Outlook References Multi-agent Interaction Structure for Enabling Subsidiary Planning and Control in Modular Production Systems 1 Introduction 2 State of the Art and Related Work 2.1 Structured Information Processing in Modular Production 2.2 Structuring Systems for Developing a Systems Design 3 Modelling Interaction for Planning and Control in Modular Production Systems 3.1 Top-Down Decomposition and Bottom-Up Aggregation of a Modular Production System 3.2 Interaction Model for Cross-System and Cross-Level Information Processing 4 Implementation of a Subsidiary Planning and Control for Enabling a Resilient Production Flow in Modular Production 4.1 Introduction of the Use Case 4.2 Implementation of a Model-Based System Structure 5 Simulation Setup and Results 6 Conclusion References Resilience to Pandemics through Flexibility in Sourcing, in Order Fulfillment, and Production Capacity of the Automotive Supply Chain 1 Introduction 2 Resilience of Supply Chains 3 Supply Chain Resilience of the Automotive Industry 3.1 Procedure 3.2 State of Art of the Automotive Supply Chain 3.3 Sourcing and Fulfillment Capabilities of the Automotive Supply Chain 4 Status Quo and Recommendations 5 Conclusion References Requirements for a Process to Remanufacture EV Battery Packs Down to Cell Level and Necessary Design Modifications 1 Introduction 2 State-of-the-Art/Literature Review 3 Analysis of a State-of-the-Art Battery System 4 Remanufacturing Challenges and Design Modifications 5 Discussion of Results 6 Summary and Conclusion References Author Index