Smart Production Technologies
-
Upload
fraunhofer-ipk -
Category
Documents
-
view
234 -
download
0
description
Transcript of Smart Production Technologies
Sustainability Global Future-proof Manufacturing
Smart Production Technologies
FUTURVision Innovation Realization
Research and Development at the Production Technology Center Berlin
INSTITUTE PRODUCTION SYSTEMS AND DESIGN TECHNOLOGY
INSTITUTE FOR MACHINE TOOLSAND FACTORY MANAGEMENTTECHNISCHE UNIVERSITÄT BERLIN
Knowledge Transfer Building Innovation Centers in Brazil
Content
04 Integrated Process and Machine Simulation
06 High-speed Manufacturing
08 Robot-assisted Repair of Turbine Blades
10 Micro-structured Gears for Offshore Wind Turbines
12 Intelligent Production through Smart Products
14 Energy-efficientAutomobileProduction
16 CooperativeRobots–TogetherWeAreStronger
18 Intuitive Robot Programming on Mobile Devices
20 Under One Common Roof
22 Building Innovation Centers in Brazil
24 New Bridges to China
26 Global Future-proof Manufacturing
30 From Silicon Valley to Silicon Sanssouci
InterviewwithCaferTosun,SAPInnovationCenter
32 SAPInnovationCenter–»Garage2.0«
CompanyProfile
33 Events and Dates
Imprint
FUTUR 1-3/2012ISSN1438-1125
PublisherProf.Dr.h.c.Dr.-Ing.EckartUhlmann
Co-PublisherProf.Dr.-Ing.RolandJochemProf.Dr.-Ing.ErwinKeeveProf.Dr.-Ing.JörgKrügerProf.Dr.-Ing.KaiMertinsProf.Dr.-Ing.MichaelRethmeierProf.Dr.-Ing.GüntherSeligerProf.Dr.-Ing.RainerStark
Fraunhofer Institute for Production Systems and DesignTechnologyIPK
Institute for Machine Tools andFactory Management (IWF), TU Berlin
Editor-in-chiefSteffen Pospischil
Compilation, Layout and Production Claudia Engel, Laura Schlutter
ContactFraunhofer Institute for Production Systems and DesignTechnologyIPK Director Prof.Dr.h.c.Dr.-Ing.EckartUhlmannPascalstrasse 8-910587BerlinPhone+493039006-140Fax+493039006-392info@ipk.fraunhofer.dehttp://www.ipk.fraunhofer.de
Printed by HeenemannDruckGmbH
Photos euspen:35(top)FraunhoferIPK:16FraunhoferIPK/BettinaSchmidt:33(top)FraunhoferIPK/KonstantinHess:17,21(map)FraunhoferIPK/JensLambrecht:18,19FraunhoferIPK/SteffenPospischil:12,13,33(bottom), 34 (top)iStockphoto/MatthewDixon:34(bottom)ThomasLohr:25NILES: 11 (bottom)SAP:31,32SFB1026:1,26,29SiemensAG:8,11(top)Stock4B-RF:BernhardManfred:14
FUTUR1-3/2012 3
turninginterdisciplinaryknow-howinto
customer-tailoredsolutionsisakeyareaof
our expertise at the Production Technology
CenterBerlin.Takingcarefulaccountofthe
tasksandchallengesofspecificindustry
branchesandmarkets,weprovidecustom-
ized consulting and support services for
the roll-out of new products, processes and
techniques.Weworkcloselywithour
customers to identify potential application
areas and establish new ones for existing
productsandtechnologies.Bothnationally
and internationally, we provide training
andtransferservicesthatbenefitusers,
manufacturersandresearchinstitutesalike.
»R&Dforahealthyeconomyandprosper-
ousregion«couldwellbethetaglinefor
our engagement in the building of na-
tionalinnovationandknowledgesystems
inAsia,LatinAmericaandtheMiddleEast.
Ourlatestprojectisprofiledinthisedi-
tion of our FUTUR magazine and shows
how wewillbeassistingSENAI,Brazil’s
National Service for In dustrial Training,
inbuilding23researchinstitutes across
the country over the next seven years.
The aim of this partnership is to provide
a pool of opportunities for professional
vocational training which will serve to
drive applied research and thus innova-
tioninBrazil.Lastbutnotleast,German
companies with local regional officesor
partnering with local companies in joint
ventureswillalsobenefit–whetherthey
be in Brazil,ChinaorDubai.
The Collaborative Research Center (CRC)
1026on»SustainableManufacturing–
ShapingGlobalValueCreation«coordinated
byProf.GüntherSeligeroftheInstitutefor
Machine Tools and Factory Management
(IWF) at the Technical University of Berlin is
one of eight CRCs funded by the German
ResearchFoundation(DFG).Established
inJanuary2012withabudgetofabout
10 millioneuro,CRC1026bringsto-
gether scientists from a range of institutes
–IWF,FraunhoferIPK,theKonradZuse
Institute Berlin, the Federal Institute for
Materials Research and Testing, and the
Social Science Research Center Berlin –
who collaborate on the development of
techniques and technologies for sustain-
able production acrosstheglobe.Thisis
an issue that could hardly be more topical,
given the present consensus that careful
use of energy, raw materials, and human
resources is critical for the conservation of
ourplanet’senvironment.Evenso,inmany
parts of the world, sustainability still does
not play a major role in manufacturing
technology.Theprojectaimstoscientifi-
cally validate the superiority of sustainable
manufacturing embedded in global value
creation over traditional paradigms of
managementandtechnology.
Read more about the new sustainability
project in this issue of FUTUR, and explore
the richrangeofourlatestR&Dsolutions
in manufacturing, automation and quality
management.
Yours,
Dear Readers,
Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann
Editorial
Research and Development4
► Parameterization and validating
Metrologicaldeterminationofunknown
model parameters for description of the
structural dynamic behavior of machine
tools is the basis for simulation of interac-
tionbetweenprocessandstructure.The
dynamic behavior of the machine tool
structure can be derived from the mea-
surement of the transmission behavior
between stimulating force and system
response at the tool center point (TCP) of
themachine.Impulsehammersandvibra-
tion exciters are the main tools used to
stimulatethesystem.Theinfluenceofthe
type and amplitude of excitation on the
capture of system response should not be
underestimated.Systemresponseismainly
registered by laser triangulators or vibrom-
eters and accelerator sensors mounted on
thetooltip.Withcertaintypesofset-up,
the weight of such sensors can exert a
markedinfluenceonthedynamicbehav-
ior of structure.
Abroadarrayofcutting-forcemodels
are available for process modeling whose
cutting-forcecoefficientsaredetermined
bycuttingtests.Adynamometercaptures
the respective cutting force yet its insertion
inthesystemalsoseriouslyinfluencespro-
cessbehavior.Experimentalstabilitymaps
are produced for validation, although laser
triangulators or sound pressure measur-
ingdevicescanalsobeused.Inanalyzing
the degree of stability, it is also necessary
to evaluate the amount of vibration the
machiningprocessitselfproduces.
► Modeling dynamic behavior
Once it has been metrologically measured,
mathematical models can be used to
map the dynamic behavior of a machine
tool.Thesemodelsprovidethebasisfor
simulation.Theresultssoobtainedoffer
a deeper understanding for optimization
of the respective processes or machine
toolstructures.Furthermore,theinfluence
exertedbyspecificsourcesoferroronma-
chiningaccuracycanalsobeanalyzed.
To succeed in competitive markets, it is essential that companies steadily
improve the productivity of their machining processes and the quality of their
products. In metal-cutting manufacturing this can be achieved by raising
the material removal rate while maintaining machining accuracy. Yet the
dynamic behavior of the machine tool structures, process parameters and
the complexity of the process itself can give rise to instabilities which restrict
the dimensional accuracy and the performance of machines. Integrated process-
structure simulation models can help to optimize process planning and control.
These models need to be parameterized and validated using a measurement-
based analysis and they have to consider the relation between process and
structure to ensure they are as realistic as possible. Furthermore, real-time
simulation of structural dynamics also enables in-process diagnostics and
monitoring of the machining process.
Machine Tools
Integrated Process and Machine Simulation
Analyzing the machining process with a dynamometer
FUTUR1-3/2012 5
Your contact
Dipl.-Ing.JanMewis
Phone+4930314-23998
Higher Wall Thickness – Higher Safety?
Astablemachiningprocessrequiresastable
machinetool.Therequirementsforsafety
technology have increased rapidly along with
theadvanceofhighspeedprocessing.This
isparticularlythecaseforthespecific
penetration resistance, which means the
penetration resistance against ejected
elementslikepartsofthetool,workpiece
ormachine.Ahigherwallthicknessof
separating safeguards, however, does not
automatically entail a higher safety for the
user.ResearchersatIWFanalyzethisphe-
nomenoncalled»kinkeffect«anddevelop
solutions to improve the dimensioning of
separatingsafeguards.
whateverstructuresaregiven.Multi-Body
Simulation, on the other hand, is primarily
used for optimization of existing struc-
tures.SDOF-andMDOF-systemsdescribe
the transmission behavior at certain points
in a structure such as at the tool tip and
are thus primarily used for the simulative
optimization of concrete processes.
To anticipate the description of the surface
qualityoftheworkpiecebeforemachin-
ing,thewholeprocessfirstneedstobe
simulated.TodothisaMDOFsystemwith
12degreesoffreedomissituatedina
MatlabSimulinkdevelopmentenvironment
and dimensioned so that the compliance
frequency response function on the TCP of
a5axisHSCmillingmachinecanberepro-
ducedwith95percentaccuracy.Further-
more, a geometric machining simulation
is modeled in Matlab and coupled to the
MDOFsystem.Thisenablesthesimulative
determination of the surface topography
asitwouldresultduringmachining.Inall
testrunsatleast80percentoftheresults
matchedreality.Whatismore,itwasalso
possible to map certain surface phenom-
enacausedbyprocessinstability.
The most commonly employed method is
the Finite Element Method (FEM) whereby
a structure is divided up into more or less
detailed volumes, in which a solution of
the governing equation describing the
physicalbehaviorispossible.Multi-Body
Simulation (MBS) is another widely used
method.Eventhoughthismethoddrasti-
callysimplifiesthestructure,withproper
dimensioning it can offer an accurate
descriptionofbehavior.Atthesametime,
itissignificantlymorerapidincomputing
dynamicbehaviorthanFEM.
Anothermoreabstractmethodisthe
modeling of the compliance frequency
response function by using spring-mass-
dampercombinations.Theseareused
in forms of Single Degree of Freedom
(SDOF) or Multi Degree of Freedom
(MDOF)-systems.Thisapproachenables
the mathematical mapping of the vibration
behavior of the TCP in the time domain
andinreal-time.
► Simulation of dynamic behavior
Depending on the area of application, each
of these methods brings its own advan-
tagesanddrawbacks.TheFiniteElement
Method is mainly used for design optimi-
zation as it can be used independently of
(a) measured surface topography, (b) simulation of surface topography, unstable milling process using a spherical cutter
Research and Development6
Machine Tools
► Pulse magnetic manufacturing
techniques
Magnetic pulse manufacturing techniques
are based on the induction principle
whereby the energy stored in capacitators
is released by using a high-current switch,
discharging bursts of high frequency high
voltagecurrentthroughthetoolcoils.
Themagneticfieldsoinducedgener-
ates alternating current in the electrically
conductiveworkpiecewhichshieldsthe
magneticfield.Injustafewmicroseconds
the Lorentz force thus produced exerts
magnetic pressure on the surface of the
workpiecewhichresultsinitsreshapingor
theweldingoftwopieces.Theirextremely
shortprocesstimemakespulsemagnetic
manufacturing techniques ideal for use in
production processes where the only limit
placed on productivity is the loading time
takenthecapacitators.Astoolcoilgeom-
etry can be varied, in combination with a
flexiblerobotsystemthisenablesavariety
of forming processes such as compression
andflatshapingtobeintroducedtothe
assemblyline.Andasprocessparameters
such as loading energy or the distance
between welding partners can be precisely
set, this also enables exact replication of
manufacturingresults.
► Pulse magnetic shaping at room
temperature
The use of various lightweight materials
offers the opportunity to reduce the
weight load across a range of application
areasformanufacturingtechnology.
Amongmetallicmaterials,aluminumand
magnesium alloys are the favored choice
forkeycomponents.Magnesiumalloys
alsoofferafurther30reductioninvolume
overaluminumwhichmakesthemespe-
cially suitable for use in the automobile
industry, and particularly in the e-mobility
sector.
Their hexagonal grid structure means that
conventionalformingprocesseslikedeep-
drawing can only be realized at tempera-
turesof220°Cforindustriallyrelevant
degreesofformation.Theircircuitboards
need to be heated with a special tool
before the forming process begins which
means higher costs and more energy for
theformingofmagnesiumsheets.
One alternative is the magnetic pulse
formingofmagnesiumalloys.The
advantages offered by pulse magnetic
manufacturing over conventional form-
ing techniqueslieintheprocess-specific
mechanisms of action which result in the
quasi-adiabaticformingoftheworkpiece.
In other words, no heat is lost during the
formationprocess.Thusitisalsopossible
to realize the forming of magnesium al-
loys with industrially-relevant degrees of
formationatnormalroomtemperature.
One basic research project is engaged in
investigating the action mechanisms that
takeplaceinsuchaprocess.Scientists
compare metal sheets formed by magnetic
pulses with those formed by conventional
processes.Pre-definedparameters(like
the hardness of the forming zone) and ap-
plicable investigations of joints are used to
delineate high-speed forming from quasi-
staticforming.Thedatathusproduced
High-speed manufacturing techniques like magnetic pulse shaping and magnetic
pulse welding offer a broad range of opportunities for extending the machining
capabilities of metallic materials. A series of research projects at Berlin’s
Technical Production Center (PTZ) are now investigating a variety of issues in
the field of the high-speed processing of metallic materials.
High-Speed Manufacturing
Geometries embossed in stainless steel at a depth of 120 µm
Your contact
Dipl.-Ing.(FH)LukasPrasol,M.Sc.
Phone+4930314-23568
FUTUR1-3/2012 7
Application Center for Microproduction
Technology (AMP)
Modernmachinestodaycanworkoncom-
ponents and structures that are as small as
100nanometers.Thiscorrespondsto10-7 m
or1/10ththethicknessofaspiderthread.
The tools of microproduction technology
are correspondingly small – and they react
correspondingly sensitively to environment
influences.TheApplicationCenterfor
MicroproductionTechnology(AMP)offers
optimalconditionsforthefinestprocessing
technologies and perfect prerequisites for
top performance in research and develop-
ment.Thestate-of-the-artlaboratorybuild-
ing is geared to the special needs of high-
andultra-precisiontechnologies.Precision
machinebuildingisoneoftheAMP’score
competences.Asaresult,multi-talented
precision machines are created in partner-
shipwithmedium-sizefirms.Theycombine
roughingandfinishingcutters,ablation
lasers, and optical in-process measurement
technologies, or an ablation laser and a
rotating, high-frequency oscillating pin for
electricaldischargemachining.
hesive bond by propelling the atoms of
two adjacent metals together to form an
atomicbond.Unliketheexplosivewelding
technique, which it otherwise resembles,
pulse magnetic welding draws its power
pulsefromatransientmagneticfieldwhich
is not only easy to operate but also en-
suressuperbreplicationquality.Scientists
use tensile testing, joint geometries,
measurement of the degree of hardness
and microscopy for characterization of
the properties and geometries of joints
inavarietyofmetalalloys.Tocutback
on lengthy sets of trials and follow-on
analyses,atthesametimeworkisgoing
ahead on the advanced development of a
FiniteElement(FE)Model.Coupledwith
electro-dynamic structural-mechanical
FE simulation, this model will help to
generate forecasts about both procedures
andqualityofwelding.TheFEmodelwill
also be used in future to help implement
parameter variations of relevant process
parameters and to optimize the overall
weldingprocess.
serves as the basis for the development of
amaterialmodelfortheAZ31magnesium
alloy into which the requirements of high-
speedformingarealsofactored.
► Molding high-strength steel
Anotherresearchprojectinvestigatingthe
molding of high-strength steel with the
aim of identifying the effects that higher
energy input with the pulse magnetic drive
haveontheformingprocess.Herethe
behavior of the forming process is critically
dependent on the speed at which forming
takesplace.Ontheonehand,highspeeds
trigger active thermal processes which
generateheat.Asthisheatisconcen-
trated in a minimal volume, it cannot
spreadthroughthewholeworkpieceifthe
processisofshortduration.Ontheother
hand, ductility and yield stress are also
dependentonthespeedofforming.And
thefrictionalpropertiesofthetool/work-
piecealsochangeasthespeedincreases.
This is particularly relevant to the shaping
of microstructures where a much larger
percentageofthesurfaceisaffected.
Aspecialsystemoftoolshasbeendevel-
opedfortheseinvestigations.Amagnetic
fieldisusedtoacceleratetheformingtool
from a few millimeters to speeds of up to
50meterspersecond.Theformingproce-
durethentakesplaceswithin60microsec-
onds.Thisenablesbetterformcompletion
than can be achieved with quasi-static
formingmethods.
► Pulse magnetic profile welding
Pulse magnetic welding creates an ad-
Schematic presentation of magnetic pulse forming using a compression coil
Schematic presentation of the coupling of an electromagnetic (left) and structural-mechanical simulations (right)
ANSYSEmag
electromagnetic
simulation
ANSYSAUTODYNexplicit
mechanical simulation
FLorentz (x,t)
Tool CoilDie
Workpiece
Switch
Coil Current
Magnetic Pressure
Capacitor Bank
Induced Eddy Current
Research and Development8
MRO
Atypicalrepairprocesschaininvolves
numerous manufacturing steps including
cleaning, build-up welding, re-contouring,
polishing,andpossiblyshotpeening.
Even today the production stages in this
chainofrepairsinvolvingmetalwork
such as surface polishing are still mainly
donebyhand.Thisdemandsagreatdeal
of experience and expertise on the part
of the operator and thus constrains the
numberofpersonnelavailableforrepairs.
Accordinglyoneoftheobjectivespursued
byengineersfromIWFandFraunhoferIPK
istomakethisstageofrepairworkfullyor
semi-automatic.Thiswouldfreeuprepair
resources and ensure the reproducibility of
repairs,whilealsoreducingrepaircosts.
► Robot-assisted manufacturing
systems
Eachrepaircaseisunique.Thisiswhy
an automated repair system needs an
adaptive process chain whereby individual
process stages and parameters can adapt
tothespecifictaskinhand.Withtheir
highflexibility,robot-assistedprocessing
systems are especially well suited for this
lineofwork.Theyalsoofferadvantages
over conventional machine tools in terms
oftheirlargerworkingareaandcompara-
tivelylowerinvestmentcosts.Thecore
of the demonstrator cell developed at
theProductionTechnologyCenter(PTZ)
is a six–axis articulated arm robot which
iscapableofworkingonevencomplex
geometrieslikethefreeformsurfacesof
aturbineblade.Aforcetorquecontrol
systemdevelopedatFraunhoferIPKis
usedtoensureasufficientlevelofpath
accuracy,evenforhighreactionforces.
Thisalsomeansthattheriskofdamageis
lower than that associated with manual in-
terventions.Theworkpieceguidedprocess
enables individual repair of components
with the required surface quality at the
respectiveworkingstation.Inaddition,
Turbine blades are highly specialized components which are subject to high
mechanical and chemical loads. For an aerodynamically optimized design,
components of modern turbo jet engines and stationary gas turbines have
to comply with close production tolerances. Additionally, the number of
highly complex parts such as »blade integrated disks (Blisk)« is continuously
increasing. Such engine components are high cost products which are often
cheaper to repair than simply replace. A group of researchers from the Insti -
tute for Machine Tools and Factory Management (IWF) and Fraunhofer IPK
is investigating how to do the best job when repairs are needed.
Robot-assisted Repair of Turbine Blades
Manual repair of turbine blades (© Siemens AG)
FUTUR1-3/2012 9
Maintenance, Repair and Overhaul MRO
MRO has a great impact on both business
and national economics: German enterpris-
es spend a fortune every day to cope with
corrosion,wear,andvandalism.Expensive
products and goods with long lifespans, as
arecommonintheenergyandtrafficsector,
showahigheconomicandscientificpoten-
tial for optimization which has so far been
ignoredbyacademicresearch.Thisisthe
point of departure for the Fraunhofer inno-
vationcluster»Maintenance,Repairand
OverhaulinEnergyandTrafficMRO«.The
clusterdevelopsenergy-efficient,sustainable
solutionsforpromisinginnovativefields
whicharetheverybasisofMRO.Those
include Condition Monitoring and Diagno-
sis,MROPlanningandDigitalAssistance,
Cleaning, and Repair and Overhaul Technol-
ogies.Theinnovationclusterincorporates
seven research institutes and 14 industrial
partners.Abudgetofabout16million
Euros for three years is provided by the
industrial partners, Fraunhofer, and the
federalstatesBerlinandBrandenburg.
For more information please visit
www.innovationscluster-mro.de
Your contact
Dipl.-Ing.FlorianHeitmüller
Phone+4930314-24962
accuratetowithinlessthan20micronsin
lessthanthreestages.Atthesametime
localized material removal rates of just a
few microns can be set with a combina-
tionofforcecontrolandfeedrate.
► Technology database
High precision results can only be achieved
through an optimal selection of machining
strategiesandparameters.Consequently,
the next stage for the scientists is to build
a comprehensive technology database
fromwhichuserscanextractallthekey
process parameters they need such as nor-
mal contact force, feed rate, and cutting
speed.
Asoneexampleofdatafeed,aseriesof
tests gave the exact material removal rates
of a variety of abrasive belt and material
combinations.Superharddiamondabra-
sive belts with their excellent stationary
behavior and low grinding-in time have
shown advantages over conventional co-
rundum belts when it comes to machining
ofnickelbasedalloys.Gainingevenmore
detailedknowledgeoftheparticularmate-
rial removal rate behavior of superhard
abrasive belts, further research on machin-
ingnickelbasedalloyswillbecarried
out.Infuture,theresearchengineerswill
particularly focus on a closer investigation
of the impact of local geometries and their
curvaturechangeinfreeformsurfaces.
abrasive belts can be used for force con-
trolled robot-assisted machining processes
onfreeformsurfacesastheycanflexibly
followallthecontoursofthesurface.
► Planning repairs precisely
For the automated repair of turbine
blades,thescientistsfirstdesignedan
intelligent process chain which began with
complete measurement of the component
toberepaired.Thiswasdonewithanop-
ticalfieldmeasuring3Dscannerbasedon
the strip projection measurement principle
whichcanquicklydigitalizethecomplex
shapes of components with a high degree
ofaccuracy.Thenetworkofpolygonsthus
produced is transformed over reference
pointsandalignedwiththenominalCAD
data set for target/actual comparison anal-
ysis.ThehighperformanceCADenviron-
ment,ROBOTMASTERforMASTERCAM,is
used as the interface for path generation
andsimulation.Asaresult,robot-assisted
machining is conducted only in those areas
displayingsignificantdeviationsfromthe
desired geometry – which saves both time
andcosts.
The next machining stage of robot-assisted
belt grinding can be reiterated for as many
timesasittakestoreachthedesiredde-
greeofcomponentquality.Todate,robot-
assisted adaptive belt grinding of simple
free form surfaces has shown results
Force-controlled abrasive head in the robot cellRobot cell for adaptive belt grinding at the PTZ
Research and Development10
Machine Tools
Offshore- wind power stations are a highly
promisingfuturemarketintherenew-
ableenergysector,andcanmakeamajor
contribution to the sustainable use of re-
sources.Onedecisivefactorunderpinning
the economic and ecological success of
the plants is their operational reliability as
maintenance and repairs on the high seas
comewithaveryhighpricetag.
► Gear impact parameters
Agear’sservicelifecriticallydependson
its particular geometry and the surface
propertiesofthetoothflank.Thelubricant
andthelubricantfilmspreadalsoplaya
role.Ifthelubricantfilmonthegeartooth
flanksistoothin,glidingmotionbetween
themcanleadtowhatisknownas»mixed
frictionwithshearing«whichresultsin
microscopicdamagetotheirsurfaces.A
reduction of surface roughness combined
with tailored surface structuring and adap-
tivemodificationofthetoothgeometry
holds out a promise of longer service life
and higher performance density for the
gearpairs.Surfacestructuringoffersa
much shorter start-up phase, higher load
capacity and an improved distribution of
thelubricantfilmduringoperations.The
challenge posed by the manufacturing of
modifiedgearsconsistsofensuringthe
flexibilityandefficiencyofthemachining
process and improving the characteristics
of the gears without unduly overtaxing
manufacturingresources.
► Structure of research
Discontinuousprofilegrindingoftooth
flanksisusedfortheindustrialmanufac-
turing of gears for offshore wind power
stations.Yetthisprocessleavesone-
directionalmachiningmarksonthetooth
flankswhichhavenegativeeffectsinthe
gear start-up phase and the distribution of
lubricantfilm.Thecurrentresearchproject
kinematicallymodulatesthegrindingpro-
cess in order to analyze and optimize the
influenceofvariousprocessparameterson
thesurfacestructureofgeartoothflanks.
The project is also investigating interaction
betweenthe3Dtoothflanktopography
andfrictionalbehaviorduringoperations.
Thefirststagehereinvolvesnumerical
simulations through which possible 3D
surface topographies can be evaluated for
their suitability in improving distribution
ofthelubricantfilm.Buildingonthe3D
structures given by the simulations, a uni-
versal cylindrical grinding machine is used
to manufacture bearing rings employing
a standard piercing process and a variety
ofaxialoscillationkinematics.Atwo-disk
testrigisthenusedtomeasuretheinflu-
ence the various structures have on the
distributionofthelubricantfilmandto
As the need for the sustainable use of resources becomes ever more urgent,
issues like raising power density, functional safety and reliability, and lowering
power consumption during production and operation are coming to the top of
the scientific agenda. A priority program of the German Research Foundation
is dedicated to the investigation of resource-efficient construction elements. In
this program, research engineers from the Institute for Mechanics, and the Insti-
tute for Machine Tools and Factory Management (IWF) at the Technical Univer -
sity of Berlin have joined forces to research ways of optimizing the manufac-
turing and operational performance of gears for offshore wind power stations.
Micro-structured Gears for Offshore Wind Turbines
Various structures ground in the surface of gears
FUTUR1-3/2012 11
Machines, Tools, Processes –
Complete Solution
NILESisoneoftheworld’sleadingmanufac-
turersofgeargrindingmachines.In1994,
the NILES product line was expanded to
includegearprofilegrinders.Asamember
oftheKAPPGroup,NILESofferstechnical
solutionse.g.forhigh-precisiongrindingof
large gears with non-dressable CBN grind-
ingwheels.Additionally,theZPlineoflarge
gearprofilegrindingmachineswasextend-
edtodiametersupto8,000mm.ThePro-
duction Technology Center and NILES have
been cooperating for many years in research
anddevelopment.PlantmanagerDr.Frank
Reichelappreciatesthepartnership:»Our
core business is customized manufacturing
ofhighprecisionmachinetools.Fundamen-
talR&Doftenfallsshort.Itisalwaysuseful
tohaveapartnerwhohasthetimetolook
atthingssystematically.«Asisthecasein
the project on micro-structuring of gears for
offshorewindpowerstations.
Your contact
Dipl.-Ing.ClemensBäcker
Phone+4930314-23923
By the end of the project, scientists aim
to deliver some well-founded statements
aboutthemechanismsofactionatwork
inkinematicallymodulatedtoothflank
profilegrinding,particularlywithregardto
chip formation, tool behavior and surface
structuring.Moreover,aqualitativereview
willalsobemadeoftheoverallbenefits
ofsurfacestructuringofgeartoothflanks
in terms of manufacturing process and
operational performance, with a particular
focusondistributionofthelubricantfilm.
checkforcorrelationswiththesimulation
results.Oncethetestphaseshavebeen
concluded, comparable structures are
producedwithatypeZE800toothflank
profilegrindingmachinefromNILES.Using
thismachine,conventionalandkinemati-
cally modulated surface structures of the
toothflankwillbeground.Ageartest
station is then used to identify the added-
valueofferedbythestructures.Long-term
studies shall weight both traditionally
ground and structured gears with a variety
of load collectives for investigation of their
mechanismsoffailure.
An offshore-wind station (© Siemens AG)
A Niles gear profile grinding machine (© NILES)
Research and Development12
SmartAutomation
The idea that products themselves can coordinate and control manufacturing
processes will soon no longer be just a sci-fi vision of things to come. Commis-
sioned by the Federal Ministry for Education and Research (BMBF), the Self-orga -
nizing Production – SOPRO project has brought together scientists from various
institutes in the Fraunhofer-Gesellschaft and the Technical University of Berlin
to develop mature applications that will make this vision reality. The basic
background idea is that machines and workpieces can communicate with one
another, learn from one another and organize the workflow on their own. The
decentralized intelligence that the workpieces and components require to do
this comes in the shape of miniaturized electronic units known as »Process
eGrains«. These can exchange information with other manufacturing units and
autonomously carry out planning, coordination and monitoring tasks.
► Product-controlled production
In a range of research scenarios such as
product-controlled manufacturing and
flexibilizationofmachine-basedmanufac-
turingflows,scientistshavealreadydem-
onstratedthatthiscanwork.Thekeyrole
in these scenarios is played by the products
tobemanufacturedandtheworkpieces
thatmanufacturethem.Withthehelpof
the Process eGrains they can call up the
manufacturing information they need at
anytime, and also have access to local in-
telligence that enables them to negotiate
with the processing stations and navigate
their own way through the production
processtothemachines.Intheseproduct
controlled manufacturing scenarios, it is
theworkpiecesthemselvesthattakethe
initiative with the aim of completing the
requisiteprocessingstagesonschedule.
Selection of the next processing station is
madethroughdialogbetweenthework-
pieces and manufacturing machines and
resources.
Product-controlled production eschews
traditional central planning and control
in favor of a multi-agent system with the
possibilities this offers for auctions and
negotiations as a means to self-organiza-
tion.Suchahighlydynamicproduction
environmentallowsforquick-off-the-mark
decision-makingaboutorderhandling,as
well as rapid responses to unforeseeable
events that do not impede the actual
productionworkflow.Decentralizedcoor-
dination between the casts of players can
rapidly compensate for such eventualities
astheoutageofamachineorworkpiece,
thelackofacomponentthroughdelaysin
just-in-time delivery services or a sudden
urgentpriorityorder.
Inmarkedcontrast,thetraditiontypeof
controlmanagementplansworkflows
in theordernetworkwithprobableex-
pectedtimesofarrivalandqueuinglines.
Thismeansthatanysignificantdelayin
schedules requires a re-calibration of the
ordernetworkandon-the-spotdecision-
makingaboutdelaysincustomerdelivery
Intelligent Production through Smart Products
Detailaufnahmen des SOPRO-Demonstrators
FUTUR1-3/2012 13
Virtual Control of Real Production
Sequences
In order to stay competitive in times of
unpredictablemarketconditions,manufac-
turers need to develop new business and
operation strategies to prosper over the
longterm.Whenforecastsbecomelessand
less accurate, it seems that the next genera-
tion manufacturing industry will require
supportforcontinuouschanges.Atthe
shopfloorlevel,thistranslatestoautoma-
tion technologies and control systems that
quicklyrespondtochangeswhilemain-
tainingastableandefficientoperation.
Advancedknowledge-basedtechnologies,
information technology support tools and
processes,asweelashighlyskilledwork-
force capabilities are required to effectively
integrateandapplythesestrategies.Anvoel
solutionhereisthe»Hardware-in-the-Loop
(HIL)«conceptdevelopedbyscientistsat
IWF.Itcanbeusednotonlytostartuppro-
duction systems virtually, but also to directly
controltherealmaterialflowbymeansofa
materialflowsimulationsoftware.
Your contact
Dipl.-Ing.EckhardHohwieler
Phone+493039006-121
deadlines.Inself-organizedproduction,
on the other hand, orders are assigned
to the appropriate machines as soon as
present circumstances require a decision to
bemade.Dueaccountisalsotakenofthe
availability of machines, the current status
oftheiroperatingequipmentandwork-
load, as well as current waiting times and
batchsizes.Theadvantagesofsuchanap-
proach to manufacturing organization are
clear for all to see: processing operations
are completed on schedule, optimal use
is made of manufacturing resources and
warehouseholdingstockisreduced.
► Demonstrating results
In order to investigate the opportunities
offered by self-organizing production,
FraunhoferIPKhasbuiltademonstrator
withsimulatedworkpiecesandprocessing
machines.Netbooksserveasworkpiece
carriers brought to the machines by a rotary
transportsystem.The»virtual«workpieces
essentially consist of nodes of wireless
sensorsandthedatastoredinthem.Their
respective processing stages and commu-
nication with the machines are visualized
ontheNetbook’smonitor.Workpiece
processing operations are simulated on
the virtual processing station which feed
in and execute the requisite processing
The SOPRO demonstrator at the Hannover Trade Fair 2012
data.Oncethepartshavebeenprocessed,
theyarereturnedtotheworkpiececar-
rier.Avirtualassemblystationtakesthe
in-coming parts and assembles them into
the product whereby the sequence of the
assemblylineisflexiblyadjustedtomeet
thein-flowofpart-componentsandcarry
outoperationsinlinewiththeworkpiece
informationreceived.
This demonstrator and the scenarios it
images can show that product-controlled
production with decentralized provision of
order and processing data is indeed a fea-
sibleproposition.Withitsapproachthat
gives objects not just memory but embed-
ded intelligence as well via Process eGrains,
SOPRO solutions can point the way to the
useofcyber-physicalsystemsofthekind
Industry4.0isnowcontemplating.First
comparisons of self-organizing produc-
tion with conventional methods of order
planning and management can point the
way to improvements in terms of expected
moreevenworkloadsandincreasesin
throughput.
Research and Development14
► Energy-oriented process models
The increasing role played by renewable
energy in the overall energy mix calls for
companies in the manufacturing sector to
becomeincreasinglyflexibleintheiruseof
energy.Atthesametimemanycompanies
haveembracedthespecificgoalofyearby
year consistently lowering the amount of
primary energy used for the manufacture
ofasingleproduct.Totheseends,the
EnEffCoprojecthastakentheautomobile
industry as a reference point in its develop-
ment of methods and tools for streamlin-
ing the capture, processing and analysis of
energymeasurementdata,andforspecific
investigations of how energy is actually
used.Theprojectengineersseektouse
cutting-edge software-based instrumenta-
tion and control equipment technology to
optimize existingplantsandprocesses.
► Uniformity of basic data
Thestartingpointforenergy-efficient
production is the in-depth analysis of
the overall manufacturing system using
realenergyconsumptionreadings.One
ofthekeyproblemsinprocessingenergy
measurement data is that even today
data is rarely available in a format from
which the required information can be
directlyderived.Moreoftenthannot,a
great number of preparatory stages must
be gone through before any meaningful
informationcanbefilteredfromtheraw
data.Moreover,giventhevarietyofdis-
parate system on which it is captured and
stored, there is also little uniform access to
dataandconsistentdatarepresentation.
Especially when it comes to basic data
likequantitiesandenergyconsumption,
tools are needed that give users effective
support in the compilation and analysis of
energyconsumptionprofiles.
► EnergyMiner
In the EnEffCo project, scientists at
FraunhoferIPKareimplementingtoolsto
achieve this consistency in the representa-
tionofdata.Adatabaseapplicationhas
been realized for frequently measured data
which retrieves data from existing systems
andstoresitinauniformmanner.This
database system is connected to a variety
oftoolsforanalysisandsimulation.The
EnergyMiner is one such tool for auto-
mated analysis.Notrestrictedtousewith
the database system, it can also handle
data from other sources such as CSV or
Excelfiles.TheEnergyMinercanalso
identify characteristic process patterns
which occur frequently during analysis of
energydata.Thesecouldbeanything
fromindividualworkingdaystothecycle
ofamachine.TheEnergyMinerhelpsus-
erstorecognizeandanalyzesuchcycles.
The advantage here is that comparing
characteristic patterns with actual process
behavior enables pinpointing of anomalies
ataveryearlystage.Atthesametime
the EnergyMiner helps users compile and
evaluateefficiencyindicatorsandenergy
efficiencystrategiesforindustrialrobots.
Making better use of energy in existing production plants and industry supply
systems, and cutting down on both energy consumption and energy costs
– these are the aims of the collaborative research project »Energy Efficiency
Controlling with Reference to the Automobile Industry (EnEffCo)«. In this
project Fraunhofer IPK is developing analysis and modeling techniques
for energy-efficient process control. This includes methods and tools for the
modeling of production processes, machines and plants, use of data mining
techniques for analysis of energy consumption profiles, and the identification
and evaluation of alternative control and process management strategies
optimized for the energy-efficient controlling of machines and plants.
Energy-efficientAutomobileProduction
SmartAutomation
Example body construction: analyzing the energy consumption of industrial robots during production
FUTUR1-3/2012 15
Your contact
Dipl.-Ing.GerhardSchreck
Phone+493039006-152
Dipl.-Ing.MoritzChemnitz
Phone+493039006-127
potentialsforsavingenergyareidentified
depending on the type of robot and the
flexibilityinthemanufacturingprocessto
dilatetherobotmotion.Towhatextent
this potential can be exploited depends
on the dormant time in the whole process
cycle.Forinstance,iftherobotitselfisnot
the system that determines the cycle time,
it can either move at maximum speed and
then wait or be in continuous motion the
wholetime.Inthisway,dependingon
the type of robot, the ideal level of energy
consumption for each cycle time can be
defined.Onefurtherpossibleoptionisto
usetheholdingbrakesandtowaivethe
engine’sholdingcurrent.
With its base in the lab results on energy
consumption of industrial robots, con-
tinual energy data recording in real-world
operations and their subsequent analy-
sis, the EnEffCo project supports efforts
towardsenergyreduction.
► Strategies for energy-efficient
robots
Energyefficiencyaspectsplayarolein
industrial robotics both for installed
systems and in the design of new closed-
loop control strategies.Inthiscontext
Fraunhofer-researchersuseFraunhofer’s
own experimental set-up with industrial
robots, without any of the imposed restric-
tions of a real-world process, to conduct
measurement of energy consumption and
identify potential for savings in energy
consumption.Indoingso,theyfollowtwo
different approaches: on the one hand
optimization of free process parameters
such as the cycle time; and on the other,
energy-optimized planning and design
oftheoverallprocess.Thelaterrequires a
highlydetailedknowledgeveryearlyon
in the planning stage of all used subsys-
tems.Asthisrequirementcannotalways
be met, scientists are concentrating on
improving existing robot programs – for
instance, by varying the maximum speed of
an industrial robot and investigating how
energy consumption varies from one mo-
tionsequencetoanother.Thisapproach
also factors intherobot’skinematicsand
theinfluenceofitscontrolunit.
For precise results the whole time be-
tween two processing cycles needs to be
investigated and not just the moment
whentherobotisinmotion.Varying
Analysis of energy consumption by an industrial robot: energy savings can be achieved if optimal use is made of the dormant periods
How to Manage Energy Efficiently
Fluctuating energy and commodity prices, a
shortage in fossil fuels, and higher customer
needs for a sustainable use of energy have
turnedenergyefficiencyintoatoppriority
forindustrialnations.In2008,theEuropean
Union has passed a set of binding legisla-
tion which aims to ensure the EU meets its
ambitious climate and energy targets for
2020.Thesetargets,knownasthe»20-
20-20«targets,setthreekeyobjectives:
reducing the EU greenhouse gas emissions,
raising the share of EU energy consumption
produced from renewable resources, and
improvingtheEU’senergyefficiency–allby
20percent.TheGermanFederalGovern-
ment has created a series of incentives to
motivate companies to implement energy
managementsystems.FraunhoferIPKsup-
ports its customers in developing energy
management systems which help to sys-
tematically monitor all energy-relevant data
andtoexhaustsavingpotentials.
Research and Development16
SmartAutomation
► Cooperative robots – cobots
Cooperative robots, or cobots for short,
are a new class of handling systems which
combine the properties of industrial robots
and manually controlled manipulators such
asweightbalancersorcablewinches.The
aim is to create a symbiosis of the best
properties of both parties: with ease of use
and low costs on the side of the manipula-
tor, and programming, web guide rolling
and precision on the side of the industrial
robot.Thisshouldenabledevelopmentof
a novel handling system that is both eco-
nomicalandergonomic.Theseinnovative
systems have recently been the object of
much intensive research under the appella-
tion»IntelligentAssistanceSystems«.
Thefirstcobotconceptisbasedonintrin-
sically passive systems set in motion and
propelledbyhumans.Fromclassicalrobots
thesesystemstaketheabilitytodefine
and regulate a trajectory along what are
knownasactivebarriersorvirtualwalls
by shifting the end-effector – the device
attheendoftherobot’sarm.Thehigh
precision of the cobot is also comparable
tothatofarobot.Thefunctionalprinciple
usedatFraunhoferIPKisbasedonanovel
continuous variable transmission (CVT) sys-
tembuiltfrommodifieddifferentialgears
that offers optimal web guiding on virtual
wallsandmaximumforceintensification
withoutendangeringhumansafety.Total
driveoutputislimitedto100watts.Force
intensificationservesheretooffsetprocess
forces such as inertia forces in the han-
dling of heavy parts or contact pressure in
assembly.Thisreducesthehumanphysical
payload to a minimum while also enhanc-
ing ergonomics and increasing productivity
andquality.Thisconceptissuitablefor
the handling of lighter payloads of up to
around100kilograms.
► Force intensification
Powerfulactivesystemslikeindustrial
robots and power enhanced handling
systems are used for the manipulation of
heavierparts.Cooperationisbasedonthe
admittance principle whereby the motion
commands or forces exerted by the hu-
manonthejointworkpiecearecaptured
by a force torque sensor and translated
intorobotmovements.Robotbehavioris
regulated so that the human can sense
the reactions of the virtual mass damping
spring system in all degrees of freedom of
movement.Theparametersofthevirtual
system can be adjusted by the controls to
fitthetaskinhandorthehuman.Foreasy
maneuverability, maximum inertia of the
objectisneverinexcessofseveralkilos.
Precision assembly and contact with a
rigid environment require a higher level of
Modern industrial robots are characterized by their precision, speed and
performance. Even so, in the foreseeable future their capabilities will come
nowhere near to rivaling the intelligence and abilities of humans. This is
why the positive characteristics of the human being and the robot make
for an ideal combination. Scientists at Fraunhofer IPK are researching novel
approaches to such a combination and implementing them as prototypes.
Two such prototypes are already in industrial use. The idea is based on direct
human-robot collaboration with physical contact, as in the case of the joint
handling or joining of an object.
Cooperative Robots – TogetherWeAreStronger
A new class of systems that combine the characteristics and functions of robots and manually guided passive manipulators
Industrial robotPrecisionPath systemSensor-based control
Passive cobot(Fraunhofer IPK)
Passivehand-guidedmanipulatorSafetyLow costsEasy to handle
ProgrammingGuiding
FUTUR1-3/2012 17
Your contact
Dr.-Ing.DragoljubSurdilovic
Phone+493039006-172
Machining with Industrial Robots
Industrial robots are now a standard prod-
uctforautomationandevenforlargework
spacesavailableatlowcost.Thereisan
increasing demand to apply robots to
machining processes which were previously
reserved for machine tools or special metal-
cuttingmachines.Aparticularchallengeis
the robot-based machining of hard materi-
als such as stone or alloys and the result-
ingdemandsontaskplanning,program-
ming,andreal-timecontrol.Engineersat
FraunhoferIPKengageinresearchand
application development for robotic mill-
ing,grindingandpolishing.Theypursuein
particular the development of innovative
solutions using robust impedance and force
control.
robotsafetystandard,setstheframework
conditions for safe cooperation, includ-
ing physical contact between robots and
humans.On-goingresearchatFraunhofer
IPKisfocusedontheevolutionofalgo-
rithms which aid in securing such require-
ments by using sensor systems to monitor
robotic and human movement on the one
hand, and by limiting robot performance
andspeedontheother.
The new cobot systems were conceived
tohelppeople,notreplacethem.Their
manual force control system is also intui-
tivewhichmakesforshorttrainingtimes.
Theyoperateassmart,easytouse,»third
handsoftheoperator«byenhancing
operators’efficiencywhilstsimultaneously
reducingtheirphysicalpayload.Direct
interactionwiththeworkersandengage-
mentwiththeirhumanskillsandabilities
meansthataveryhighlevelofflexibility
canbeachieved.
damping.Afurtheradvantageisthatthe
controls can generate virtual active and
passiveobstacles–knownasvirtualwalls
and guides – as this facilitates human lead-
ershipintheassemblyofcomplexparts.
FruanhoferIPKhasrecentlydeveloped
aflexibleforceintensifiedrobotforthe
semi-automatic assembly of windscreens
and rear windows for the automobile in-
dustryintheEUproject»FlexibleAssembly
SystemsthroughWorkplace-Sharingand
Time-Sharing Human-Machine Coopera-
tion(IP-PISA)«.Inthissystemthehandling
of the screen – from the bonding station
toitstransporttothecarbodyandtrack-
ing of assembly line movement – is fully
automaticandrobot-controlled.Twohu-
man operators collaborate with the robot
ontheactualassembly.
► Safety
Stable and transparent robot behavior
during interaction with humans, and the
safety of human operators are critical
for the acceptance and use of force-
intensifiedcooperativerobotsinindustry.
Aboveall,particularattentionmustbe
paid to the high power output of robots
whichatseveralkilowattscancausevery
seriousinjuries.ISO10218-1,2,thenew
Semi-automatic windscreen assembly by cooperative robots
Passivehand-guidedmanipulatorSafetyLow costsEasy to handle
Research and Development18
SmartAutomation
Smartphones and Tablet PCs are wowing private users with their high func-
tionality, ever greater capability and ease of use. In an industrial context these
handheld sets can be used as mobile control and programming devices. In view
of the ever more rigorous requirements placed on the man-machine interac-
tion (MMI), developers and users expect that such devices will put a new lease
of life into the planning, programming and maintenance of automated produc-
tion systems.
► Multimodality – communication
over multiple channels
Themodelonwhichthedesignofefficient
ergonomic man-machine systems is based
is nothing less than natural person-to-
person communication using the mediums
oflanguageandgesture.Multimodality,
or the simultaneous or sequential use of
multiple communication channels, plays
a major role in the design of high perfor-
mancecontrolsystems.Oneprerequisite
forthedesignofanefficientanduser-
friendly MMI system is an application and
user-specificblueprint.Typically,multimod-
al control systems use movements of the
fingersandhands,andgesturesoftouch
as well as language for communication,
but visualization is another form of inter-
actionbetweenhumansandmachines.
Apartfromclassicaldisplays,methodsof
AugmentedReality(AR)canalsobeused
for the visual presentation of information
inacameraimage.Inthefieldofindustrial
robotics, users are supported by spatial
informationaswellasrobotprograms.In
this way poses, trajectories, coordinate
systems and other data for processing
tasksinareal-worldrobotenvironment
canbevisualized.Whatismore,avirtual
industrial robot can simulate the programs
withouttherealrobothavingtomakea
move.Inthistypeofevaluation,theuser
isnotconfinedtoanyparticularcomputer
workstationasheadmounteddisplaysor
handhelddevicesarequitesufficientfor
visualizingwhatishappening.
► Programming by Demonstration
OneofthekeyfocalpointsofR&Dat
the Institute for Machine Tools and Fac-
tory Management (IWF) at the Technical
University of Berlin is control-by-gesture,
visualization and virtual interaction for the
programmingofindustrialrobots.This
engages with Tablet PCs but also with 3D
motiontrackingsystems.Unlikestandard
programming techniques, these enable
veryrapiddefinitionofposes,trajectories
Intuitive Robot Programming on Mobile Devices
Easy programming: the human operator shows how it is done and the Tablet PC follows suite
Segmentation of hands and extraction of finger tips for gesture recognition (left), interaction with virtual objects for definition of an assembly operation (middle), transferring the task to an industrial robot (right)
FUTUR1-3/2012 19
Secure Identity – Uniqueness und
Authenticity in the Real and Digital
World
TheFraunhoferinnovationcluster»Secure
IdentityBerlin-Brandenburg«isacollabora-
tionbetweenfiveFraunhoferinstitutes,five
universities,12companies,aswellasthe
LänderBerlinandBrandenburgalongwith
individualinstitutionsinotherfederalstates.
Goal of the joint research and develop-
ment projects is to provide technologies,
processes and products that enable the
unambiguousverificationoftheidentityof
individuals,objectsandintellectualproperty.
Such identity security ensures that identity
can be used in many different ways to sim-
plify processes in commerce, administration
anddailylife.Theapplicationsrangefrom
the next generation of tamperproof per-
sonal documents, the security of electronic
business processes, through to communica-
tion between machines and vehicles, and
productandbrandprotection.Findmore
information on www.sichere-identitaet.de
Your contact
Dipl.-Ing.JensLambrecht
Phone+4930314-28689
modelingoftherobotintheARapplica-
tion means that the robot programs can
besimulatedinareal-worldenvironment.
The robot programs can be simulated in
areal-worldcontextandcheckedforthe
achievability of individual poses, as the
robotisvirtuallymodeledintheARap-
plication.
BycombiningtheARapplicationwith
3D gestures, a new form of interaction
is created whereby the use can interact
with virtual objects shown in the camera
picture.Thismeanstheusecantypically
move, rotate or scale these objects and
thusdefinesingleposes,trajectoriesand
tasks.Therobotprogramisadaptedto
eachrespectiveinteractionwhiletheAR
application also enables simultaneous
feedback.Ifthevirtualprogrammingis
successful, it can be directly transferred
from the handheld device to the industrial
robot’scontrolsystem.
► User-friendly apps
The result is a spatial program interface for
industrialrobots.Theactualprogramming
environment runs as an app on conven-
tional smartphones and Tablet PCs and in-
cludestheAugmentedReality-application.
The programs can be transferred from the
app to the industrial robot over a common
interface or to other simulation tools via
additionalinterfaces.
andtasksasthereisnolongeranyneed
to spend time moving the real industrial
robot.Instead,thesystemusessimple
gesturestoproduceposesandtrajectories.
Atthesametime,informationisfedinto
the robot program of a handheld device
for further administration and processing
ofthewebdata.
Scientistsinvokethe»Programmingby
Demonstration«principletoprovethatro-
bots really can be simply programmed us-
ingsmartphonesorTabletPCs.InthePbD
paradigmapersonfirstdemonstrateshow
aparticulartaskistobeaccomplished,
and a smartphone or Tablet PC then
automatically computes the corresponding
programfortherobot.Thisformoftask-
orientedprogrammingrequiresnospecific
expertisewhichmakesitespeciallysimple
foruserstoexecute.Allitrequiresareob-
jects which the user can grasp, move and
put down together with an image-assisted
sensor system which can recognize and
trackthem.Complexrobotprogramsare
extrapolated out of the recorded trajecto-
riesoffingers,handsandobjects.
► Testing with Augmented Reality
Such a robot program is evaluated with an
AugmentedRealityapplicationontheTab-
letPC.Duringoraftertheinteraction,it
givesvisualfeedbackbyfadingincurrent
programming information simultaneously
to the user interaction as virtual objects in
thecameraimageoftheTabletPC.Virtual
Simulation of a robot program in Augmented Reality
20 Research and Development
A model-based integrated management system can bring together various
different management systems for quality, industrial safety, environmental,
energy and risk management under one common roof. Model-based integrated
management systems are built on a company model in which all relevant busi-
ness processes are mapped. In a pilot project of the Fraunhofer-Gesellschaft,
Fraunhofer IPK has developed an integrated management system precisely
tailored to the particular needs and requirements of research institutes. First
rolled out in the Fraunhofer Heinrich Hertz Institute HHI with support from
experts at Fraunhofer IPK, the system will be established in other institutes
in the near future.
process architecture is of the essence if
newstaffmembersaretofindtheirbear-
ingsquicklyandeasily.Functionalitiesfor
maintenanceandupkeeparealsoneeded
that can be operated even under limited
personnelresources.
► A process-oriented and participa-
tory approach
ColleaguesfromFraunhoferIPKusedtheir
own MO²GO software tool to engineer a
corporate model as the information base
► User-friendly and legally compliant
working conditions
Inthefieldofresearch,developmentand
fabrication of photonics, Fraunhofer HHI
hasbeenworkingsince2010withaQuali-
tyManagementSystem(QMS)certifiedper
ISO9001.InthismoveFraunhoferHHIhas
not only responded to the requirements of
itskeystrategicpartners,butalsosought
toraisethequalityprofileofitsprocesses
andproductsintheoutsideworld.InApril
2011acertificationlevelprocess-oriented
QualityManagementSystemwasintro-
ducedcoveringthewholeinstitute.In
thenextstagethisQMSwillbegradually
extended to include management systems
for industrial safety and environmental
management.Roll-outforthesesystems
is plannedfor2013.
With the introduction of such systems,
staff and management at Fraunhofer HHI
wanttocreateworkingconditionsthat
are both user-friendly and legally compli-
ant.Researchinstituteshavetheirown
unique set of requirements for integrated
managementsystems.Forinstance,the
relativelyhighfluctuationofpersonnelin
research departments means that intuitive
forFraunhoferHHI’sintegratedmanage-
mentsystem.Processesthatalreadyful-
filledtherequiredqualitystandardswere
takenasbenchmarks.Workshopswith
the whole cast of actors then used these
benchmarkstoadaptthemodeltothe
institute’sownspecificsetofrequirements.
Useofthesebenchmarksandquality-
related documentation saved resources
and ensured that the whole model could
berapidlycompletedinjustsixmonths.
Allrelevantdocumentswerecentrally
Under One Common Roof
Advantages of an IMS over single systems
QualityManagement
FUTUR1-3/2012 21
archivedinaProcessAssistantandsoft-
waresystemsforworkflowsupportwere
integrated to offer staff members optimal
proactiveassistanceintheirdailywork.
Such a participatory approach enables
quality management for human resources
tobesimultaneouslyqualifiedformodel-
ingmethodsandsoftwaretools.
Atthesametimeaqualityorganization
system with standardized role concepts
was also engineered, modeled on various
Your contact
Dipl.-Ing.PhillipKarcher
Phone+493039006-181
Dipl.-Ing.NikolausWintrich
Phone+493039006-252
successfulreferenceprojects.Thisconcept
envisions that the role of quality manage-
mentofficerswillbetakenbyvarious
professionals who coordinate depart-
mental system-relevant activities such as
processoptimizationorinternalauditing.
FraunhoferIPKassistsHHIinthetraining
andprofessionalqualificationofquality
managementofficers,qualityassistants
andinternalauditors.
Eco-Quality – Quality Management
goes Green
The quality of a product is more and more
definedbythequestion,whetherithas
beenmanufacturedinasustainableway.
Therefore,itmakessensetodefinequality
management no longer exclusively along
economic parameters, but along ecological
onesaswell.Energyefficiency,preservation
of resources, and sustainability also become
qualityfactorsforproductsandprocesses.
Onbehalfofitscustomers,FraunhoferIPK
delivers a foresighted quality plan as well as
a comprehensive requirements and con-
figurationmanagementfortheentirelife
cycle of products, which naturally includes
sustainabilityaspects.
The Process Assistant as a model-based integrated management system
► High customer satisfaction
Single processes of the integrated
management system have already been
activatedin2012.Theentiresystemis
plannedtobeavailableinspring2013.
The staff at the Fraunhofer Heinrich Hertz
Institute’stwositesinBerlinandGoslar
are very happy with the implementation of
theproject.AsJörgStohl,administrative
directoratFraunhoferHHIcomments:»In-
troduction of the model-based integrated
management system has meant that we
have been able to introduce greater trans-
parency into our business processes for all
ouremployeeswhilealsosignificantlycut-
ting down on the time and effort needed
for maintenance and updating of process-
relateddocuments.What’smore,wehave
also achieved a much higher degree of
legalcertaintyinthefieldsofworkplace
safetyandenvironmentalprotection.The
systemmakesamajorcontributionto
certificationandcollaborationwithpublic
authorities.«
International Cooperation
Interview
BUSI
NES
S M
OD
EL
22 Research and Development
Integrated Strategy Development Mode
Building Innovation Centers in Brazil
► Fraunhofer know-how for Brazil
Brazilisoneoftheworld’sfastestgrowing
economicregionsandin2012itseconomy
rose to become the sixth biggest in the
worldintermsofnominalGDP.SENAI,(the
acronymforServiçoNacionaldeApren-
dizagemIndustria)hasasolidtrackrecord
ofprovidingvocationaltrainingtoover55
millionpeopleat800differentoperational
units.SENAIisfinancedbytheBrazilian
Confederation of Industry which is
responsible for professional and vocational
trainingandwhichalsoseekstocultivate
internationalbusinessrelationships.
With the newly planned research insti-
tutes,SENAIintendsnotjusttopromote
vocational training for industry and busi-
ness, but also to promote applied research
acrossthecountry.Thisiswhyaparticular
focus of these innovation institutes will be
on drawing up development projects for
Brazil’semergingindustrysectors.
The strategic cooperation pact covers a
sevenyearperiodinwhichFraunhoferIPK
willassistSENAI,itsBrazilianpartner,in
theconstructionofatotalof23innova-
tion centers across nearly all federal states
in Brazil, and in establishing a central
administrative unit in Brasilia, the coun
try’scapital.Inthefirstprojectphasefrom
2012to2013,expertsfromFraunhofer
IPKwilldevelopbusinessplansforanini-
tial number of eight innovation institutes
and a management concept for the central
On 21 June 2012, Fraunhofer IPK signed a cooperation agreement with SENAI,
Brazil’s National Service for Industrial Training. Fraunhofer IPK will assist SENAI
over the next few years in the construction of 23 research institutes in Brazil.
Fraunhofer experts will draw up the business plans for national management
as well as the planned SENAI institutes and develop management solutions
for individual establishments.
unitinBrasilia.FiveotherFraunhofer
Institutes are also providing additional
technicalknow-howfortheproject.
► Best Practices in R&D Management
The start-up phase of the project involves
the compilation of in-depth business plans
for the innovation institutes specialized
inthefieldsofautomationtechnology,
electrochemistry, renewable energy, lasers,
micro-production technology, surface en-
gineering, polymer technology and virtual
productdevelopment.Inafirststage,the
directors and deputy directors of the insti-
tutes together with future staff members
of the administrative unit were invited to
atrainingseminaratFraunhoferIPKfor
capacity building in the planning and man-
agementofresearchanddevelopment.
In the seminar, Fraunhofer Best Practices
in research and development manage-
ment were presented for preparation and
operational support while an analysis of
the impact that political, economic, social
and technological factors can have on the
research landscape gave a clear idea of
theframeworkconditionspertainingin
Brazil.Theseresultswerefactoredintothe
evolution of a strategy planning process
in the course of a moderated participatory
workshop.
Methods such as integrated strategy devel-
opment which were originally developed
Your contact
Dr.-Ing.HolgerKohl
Phone+493039006-168
Prof.Dr.h.c.Dr.-Ing.EckartUhlmann
Phone+493039006-100
R&D Strategy for Dubai
In2010,FraunhoferIPKsupportedthe
Dubai Institute of Technology (DIT) in
launching its new research and development
strategy.Thiscampaignaimedtobuilda
platform to assist in the targeted promotion
ofresearchanddevelopmentinspecific
regionalsegments.Truetothemotto»R&D
for a healthy economy and prosperous
region«IPKconsultantsadvisedDITinthe
developmentofatechnologyframework
to regulate both internal activities in the
institute and university-led development
of economic sectors closely related to the
institute.Havingdevelopedthebusiness
plan and its related implementation plans,
DITinpartnershipwithFraunhoferIPKhas
now moved on to a further project stage
and initiated research funding programs as
wellasfirstresearchprojects.
with the corporate sector in mind, were
tailoredtomeetthespecificneedsof
researchinstitutes.Buildingontheinsights
gained in the planning of technology
parksandnationalinnovationsystems,the
strategic development process was then
initializedfortheinnovationinstitutes.To
validate this process and coordinate it with
actualmarketconditions,IndustryWork-
shops assessed the potential of the innova-
tioncentersinrelationtoindustrialneed.
In this way, a detailed plan for products
and services could be developed which
both related the potential of the planned
productportfoliowiththespecificneeds
ofindustrycustomers,anddefinedstrate-
gicbusinessareas.Follow-onTechnology
Workshop,heldincooperationwithse-
lected Fraunhofer Institutes specialized in
thesefields,thenestablishedthespecific
requirements of the Innovation Centers in
terms of human resources, equipment and
infrastructure.Averifiedfinancingplan
and an operational plan factored in both
envisioned research activities and capacity
planningforproductandservicedelivery.
Eight business plans were evolved out of
this set of partial results which mapped
strategic and operational planning on the
highestlevel.
Roadmap of the Business Plan for the Innovation InstitutesIntegrated Strategy Development Mode
t
International Cooperation
24 Research and Development
and mechanical engineering so that we
nowhavequiteanextensiveR&Dnetwork
inChinaatourfingertips.
FUTUR:Whatkindofworkdoesyournew
appointmentasAdvisoryDeaninvolve?
Uhlmann:MyprimaryroleasAdvisory
DeanistoadvisetheDean,Prof.Yang
Zhigang,onthedevelopmentofstrategy
for the College of Mechanical Engineer-
ing.Apartfromthis,Iamalsoresponsible
for furthering international relations at
theCollege.Amongotherthingsweare
striving to set up collaborative research
projects – for instance partnerships which
could be funded by the German Research
Foundation (DFG), the Federal Ministry
of Education and Research (BMBF) or the
Chinese Ministry of Science and Tech-
FUTUR:Prof.Uhlmann,howlongdoesyour
associationwithTongjiUniversitygoback?
Prof. Uhlmann: For seven years I gave
aseriesofblocklecturesthereonrapid
prototypingandrapidmanufacturing.Dur-
ing that time I built up a comprehensive
networkofcontacts,includingcontacts
withindustry.MyworkatTongjiUniver-
sityalsoledtomyappointmentin2003
as an Honorary Professor at the univer-
sity’sSino-GermanCollege.ThisCollege
was founded in 1998 as a joint project
betweentheDAADand Tongji University
in Shanghai, and sees its role as a bridge
linkingtheGermanandChineseeduca-
tionsystems.EvenwhenIhadstopped
workingasalecturer,Istillcontinuedto
extendmynetworkofscientificcontactsin
thefieldsofmanufacturingtechnologies
nology(MOST).Wearealsodeveloping
research concepts that closely engage with
FraunhoferIPK.Anotherkeyaspectofmy
officeisassistingcurriculumplanning.At
the moment, we are involved in setting up
aDualDegreeMaster’sPrograminProduc-
tion Engineering which will drive forward
the structuring of curriculum planning at
both Tongji University and the Technical
UniversityofBerlin.
AnotherfocalpointissettingupaFraunhofer
IPKprojectgroupat Tongji University which
will involve colleagues from Tongji University
and the Sino-German College in projects
on manufacturing technology and machine
tools.Wearelookingtoworkshoulder-to-
shoulderwithindustryintheseprojects.The
project group is mainly geared to German
machine tool and plant constructors with a
footonthegroundinChina.Generallyspeak-
ing, German companies in China do not
have their own research departments, so
wehavemadeitourgoaltoworktogether
with companies from Germany or companies
involvedinjointventureswithChinesefirms
to strengthen their innovation and overall
productivity.
Finally, it is one of my duties to maintain
and develop the exchange of academic
personnel.Today,theProductionTech-
nology Center hosts a large number of
Chinese scientists who are very success-
fullyworkingontheirPh.D.sthere.
Prof. Yang Zhigang, Dean of the Faculty of Mechanical Engineering at Tongji University, hands Prof. Eckart Uhlmann his accreditation as Advisory Dean.
On 18 May 2012 the College of Mechanical Engineering at Tongji University in
Shanghai, China, appointed Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann as its Advisory
Dean. Tongji University, one of the most prestigious of China’s universities,
was founded in 1907 by German scientists. At present, over 55,000 students are
enrolled there. In 2003, Prof. Uhlmann was appointed as Honorary Professor at
Tongji University‘s Sino-German College. His new appointment as Advisory Dean
is for a five year period. Futur talked to Eckart Uhlmann about his new respon-
sibilities and the future of Sino-German collaboration in industry and science.
New Bridges to China
FUTUR1-3/2012 25
FUTUR: You touched on the Dual Degree
Master’sPrograminProductionEngineering.
Howfarhaveyougotwiththeplanning?
Uhlmann:TheideaforaDualMaster’s
Degree in Production Engineering came
fromajointworkshopheldthissummer
with the Technical University of Berlin and
TongjiUniversity.Atthemomentweare
workingoutthedetails.Weareplanning
for equal numbers of German and Chinese
studentstotakethefivesemesterprogram
atbothuniversities.Weexpectthestu-
dentswhoapplyforsuchaMaster’spro-
gram to have not only excellent academic
results, but also a high level of interper-
sonalskillswhichwewillscreenthemfor
inindividualselectioninterviews.Ontop
of this, they will also need excellent lan-
guageskillsasthelectureswilleitherbein
EnglishorGerman.Courseswhichteach
the basics of the respective languages and
culturesalsoformpartofthecurriculum.
German companies put a big premium on
engineerswhocanspeakChinese,and
ourDualMaster’sDegreeisaresponseto
meetthisdemand.Wefullyexpectthat
we will be able to start the program in the
firstquarterofnextyear.
FUTUR:AsAdvisoryDeanyouwilloften
beinChinaoverthenextfiveyears.How
do you see collaboration with China devel-
opinginfuture?
Uhlmann:Intermsofourownspecific
case, I see intense collaboration between
Tongji University, the TU Berlin and the
Fraunhofer-Gesellschaft.Infiveyearsour
Master’sinProductionEngineeringshould
be so well established that perhaps we
willbetakingasmanyas50studentsand
notjustthepresentfivetoten.Obviously
at the same time we also want to con-
tinue with our discussions and exchanges
ofviewswithotheruniversities.Atthe
moment, apart from Tongji University, we
alsohavebondswithJiaotongUniversity
inShanghaiandXi’an,andareinclose
contact with the Technical University of Da-
lianandBeijingUniversity.Thismeansthat
we can extendourinternationalnetwork
– not just between people but between
institutionsthemselves.Theworldisgrow-
ing closer and closer together; even today
itisjustonebigglobalmarketplace.And
this does not just apply to business – it
alsoappliestoscience.Ourprimarygoal
still remains to use the leverage of innova-
tion through teaching and research to
assist in the further development of Ger-
man business in China and to sharpen its
competitiveedge.
Interview by Bettina Schmidt
The Sino-German College for Graduate
Study
Ajointeducationalprogrambetweenthe
DAADandTongjiUniversity,eversinceits
foundation in 1998, the Sino-German Col-
legeforGraduateStudy(CDHK)hasbeen
the most successful academic exchange
programbetweenGermanyandChina.
Students at the College from all over China
cangainaMaster’sDegreeattheFaculties
of Electro-technology, Mechanical Engineer-
ing, Business Management and Commercial
Lawoveratwotothreeyearstudyperiod.
WelloverhalfofCDHK’sstudentsreceivea
scholarship for a semester of study at a uni-
versityabroadoraninternshipinGermany.
Furthermore, there is also the opportunity
totakeaDualMaster’sDegreeatoneofthe
German partner universities, the Technical
University of Munich or the Ruhr University
inBochum.OneuniquefeatureoftheCol-
legeisitsrangeofsome30professorships
fundedbyover20leadinginternational
companies.Lecturesandteachingaregiven
by both Chinese academics who have either
studiedinGermanyortakentheirPh.D.s
there, and by over two dozen German visit-
ingprofessorswhogiveblocksoflectures.
Your contact
Prof.Dr.h. c.Dr.-Ing.EckartUhlmann
Phone+493039006-100
26 Research and Development
Collaborative Research
Turnabout in energy policy, electro cars, passive houses – the search for new
ways of life compatible with the future dominates the public forum. The
Collaborative Research Center (CRC) 1026 on »Sustainable Manufacturing –
Shaping Global Value Creation« took up its work to coincide with the official
»Science Year 2012 – The Year of Sustainable Energy for All«. In this interdisci-
plinary large-scale project funded by the German Research Foundation (DFG),
50 scientists are developing sustainable production technologies and strategies
with the aim of enabling a higher level of global prosperity with less consump-
tion of resources.
► More than just technology
Given the exponential growth in the
marketsofemergingcountriesandthe
staggering consumption of resources by
industrialized nations, rationally consid-
ered, there is no alternative to more sus-
tainableformsofproduction.AsProfessor
GüntherSeligeroftheInstituteforMachine
Tools and Factory Management (IWF) at
theTechnischeUniversität(TU)Berlin,and
spokespersonofCRC1026comments,»We
understand production as an integral part of
aglobalnetworkofactors,interestsand lo-
calconditions.Makingapositiveinterven-
tioninthisnetworkisthehighlycomplex
challengewhichwehavesetourselves.«
Sustainable production technology means
alotmorethanjustpuretechnology.It
must be oriented to future needs, and
mustfitinwith,orbecapableoftrans-
forming, existing production structures
inthecompetitiveglobalmarketplace.It
must satisfy social requirements, pass mus-
ter when appraised environmentally, and
holdoutthepromiseoffinancialrewards.
Finally,likeanyotherformofinnovation,
it must be compellingly presented if it is to
findapplicationintherealworld.Allthese
requirementsarereflectedintheholistic
research program set up by the Collab-
orativeResearchCenter1026.Solutions
for production technology are embedded
Global Future-proof Manufacturing
Future global development if continued use is made of present production technologies and paradigms
2050
2012
intheStrategyDevelopmentandKnowl-
edgeTransferprojectareas.AsProfessor
Seligerexplains,»Onlybykeepingyour
eye on the big picture can you hope to
drivesustainableprocesses.Sustainability
isalwaysmultidimensional.«
► From theory to practice
Suchahighlycomplexundertakingneeds
acrystalclearstrategy.Asthefirststepin
the development of future-proof technolo-
gy involves estimating the extent of future
needs,IWFexpertsengagedinCRC1026
use scenario techniques to project current
development trends into the future, fac-
toring in a broad array of possible political,
social,ecologicalandtechnologicalinflu-
ences.Theresultantscenariosshowwhich
challenges await the global community
and also provide the point of departure for
thequestforsolutions.
AtthesametimescientistsattheTU
Department of Environmental Technology
and the TU Department of Landscape
ArchitectureandEnvironmentalPlanning
areworkingongivingsustainabilityideas
– which are often highly abstract in nature
–aspecificengineeringandeconomic
cast.Thisisdonebydefiningthecriteria
for sustainability and applying them to the
organization of technical production for
globalvaluecreationnetworks.Research-
are developing a tool for the analysis of
business processes in global value creation
networks.Thistoolpresentsthereper-
cussions of single actions in the overall
contextoftheglobalproductionnetwork,
and thus helps actors assess the scope of
theirdecision-making.
»Withthemethodologicalapproach
adoptedbyourresearchwork,wecover
the whole array of technological possibili-
ties,«saysProfessorSeliger.»Suchbreadth
is one important pillar of our project; its
exemplarydepthisanother.Wetake
selected examples of production technol-
ogy and show the potential of technol-
ogy rigorously oriented to sustainability
criteria.«Exemplarysolutionsforproduc-
tiontechnologyidentifiedbyCRC1026
comeinthefieldsofproductdevelopment,
manufacturing techniques and machine
tools – focal points of IWF expertise and
centralelementsinvaluecreation.
► Concrete solutions
In this way, early in the development
phase, the constructor sets product char-
acteristicsandparameterstodefinemany
properties of relevance to sustainability for
theproduct’swholelifecycleormultiple
phasesofuse.Modularization,for instance,
can enhance subsequent functional prod-
uct properties and either enlarge or limit
ers develop sustainability indicators, test
them for utility and integrate them in
evaluation procedures as orientation aids
forglobalproduction.
When it comes to the evaluation of sus-
tainability and extrapolation of proposals
foraction,mathematiciansattheKonrad
ZuseCenterforInformationTechnology
Berlin and the Department of Mathemat-
ics at the TU Berlin play a special role in
CRC 1026.Asequalaccountmustbe
takenof all three dimensions in sustain-
ability – the economic, the environmental
and the social – this can give rise to con-
flictsintheformulationofactionproposals.
Clashes of interest can occur, for instance,
whenaspecificmeasuremakesaprocess
much more environmentally friendly but at
the same time raises its cost, or when the
waytoimprovedworkingconditionsneces-
sarily involves a shift in environmental pol-
lution.Toarriveatthebestpossibleforms
of compromise in such situations, but
also to include the time needed for the
implementation of new measures in the
evaluation, scientists apply the theories of
‘MulticriteriaOptimization’and‘Dynamic
Systems’frompreviouslyseparatefieldsof
mathematicstothispracticalapplication.
Together with the quality science special-
istsfromIWFandexpertsinknowledge
managementfromFraunhoferIPK,they
A blueprint for integrating adaptronic systems into machine tools from the CRC 1026 »Technological Solutions« project area
FUTUR1-3/2012 27
28 Research and Development
Collaborative Research
manufacturingintheshortterm.Onthe
one hand, IWF engineers focus on the
reconditioning of used machine tools and
increase the precision of old machines
byfittingthemwithadaptroniccompo-
nents.Suchalowcostmethodprolongs
the lifecycle of existing machines and also
opens the way to the global value creation
networkforactorswholackthefinancial
resourcestobuynewequipment.Onthe
other hand, researchers are joining forces
with experts from the TU Department
of High-Frequency and Semiconductor
System Technologies in the construc-
tion of novel machine tool mounts with
optimizedmicrosystems.Theirmodular
construction enables easy replacement of
singlehigh-techcomponentsforefficient,
needs-basedconfigurationoftheoverall
system.Thismakesplantequipmentmuch
moreflexibleandmeansthatinfuturethe
roll-out of new sustainability solutions in
existingproductionwillbemuchquicker
andlessexpensive.
► Knowledge is the future
KnowledgeTransferwasanchoredasthe
thirdkeythemeintheCRCresearchpro-
gramfromtheverybeginning.Professor
Seliger explains the reasoning behind this
ratherunusualmove,»Ourstrategicand
technologicalworkisallwellandgood,
butitonlymakessenseifwecansucceed
in communicating our results to the out-
side world in ways that it can follow and
accept.Wemightbethepeopledevelop-
ingthesolutions,butit’sotherpeople
whowillactuallyusethem,andit’sthem
thatwe’vegottocommunicatewith!«In
this context the CRC approach is squarely
overeducationandqualificationforthe
broad masses with the aim of dramatically
raising the level of teaching and learning
about sustainable production across the
wholeworld.
Apartfromtheevolutionoftechnical
information tools that should help
decision-makerskeeptheirattentionfixed
on sustainability, another line of investiga-
tion lies in researching social phenomena
likewillingnesstocooperatewhichis
so critical for the success of sustainable
businessmanagement.Scientistsatthe
Social Science Research Center Berlin
(WZB)areinvestigatingincentivesystems
forsustainablecoursesofaction.Ina
series of experiments modeled on game
theory, they are exploring the conditions
under which people can act together as
acollectiveinordertosolvecertaintasks,
and examining the factors which impact
ontheirdecision-making.Atthesame
time experts at IWF are analyzing existing
methods for teaching and learning in
terms of issues connected with sustain-
ability.Andtheyaredevelopingwhatare
knownas»learnstruments«–technical
artefacts which automatically communi-
catetheirfunctionalitytotheuser.With
thesetools,workersandprivateindividu-
alsalikecantrainthemselvesintuitively
and autonomously in the operation of
novelproductionmachinesandprocesses.
Learnstruments, therefore, can overcome
language barriers and address a variety of
qualificationlevels.
Automatedfeedbackofthekindmod-
eled in CRC for man-machine interaction
is yet another approach: camera systems
and image recognition are used to analyze
movementsmadebytheworker.While
the movement is being made, a monitor
screen shows both the results of an ergo-
nomic assessment and proposals for move-
mentcorrection.Suchasystemisamajor
step forward in terms of enhancing safety
attheworkplace.Andsuchfeedback
guidance can also be used for advanced
operationaltrainingonthemachines.
them depending on various local develop-
mentlevels.
The product development experts at IWF
deal with such dependencies between the
functional design of a product and its sus-
tainablecharacteristics.Theyareworking
to develop an assistance system to support
decision-makingbasedonsustainability
criteriainproductlifecyclemanagement.
The aim here is to enable designers and
constructors to get a clear picture and
focus on the economic, environmental and
social impact of a product over the whole
productlifecycle.
Once a product is designed, its production
canbegin.Machining,welding,cooling
and cleaning are all standard procedures
in parts manufacture and assembly that
are often associated with heavy use of
resources.Useofaclosedinternalcool-
ing system in the tool during turning or
milling operations should largely do away
with the need for cooling lubricants which
need repeated chemical restoration during
standardoperations.IWFisdevelopingthe
prototype of a system with an internally
cooledcuttingtoolforlathes.Useofthe
modern dry ice blasting cleaning tech-
nique can further reduce the need for
chemicalsubstances.Andwhenitcomes
to optimization of joining processes, sci-
entists are concentrating on how to save
energy through a combination of simula-
tion and innovative process technologies
suchascombinedweldingmethods.
Machine tools are the heart of industrial
manufacturing and are mainly highly
robustinconstruction.Amillingmachine
thatcomesontheusedtoolmarketgener-
allyhas30yearsofservicelifebehindit.
YetCRC1026followsatwotrackstrategy
in order to give sustainability to global
11th Global Conference on Sustainable
Manufacturing GCSM
23–25September2013,Berlin
Visit the Global Conference on Sustainable
Manufacturing GCSM and learn more about
theincreasingsignificanceofsustainable
manufacturingasaglobalmegatheme.
GCSM is geared towards representatives
of science and industry from all continents
interested in the ecological, economical
andsocialdimensionsofsustainability.The
conferenceofferskeynotespeeches,panel
discussions, parallel sessions and a poster
forum.Discussionsandexchangeofideas
between the participants are an integral
partofthemeeting.Formoreinformation
please visit www.gcsm.eu
Your contact
Prof.Dr.GüntherSeliger
Phone+4930314-22014
FUTUR1-3/2012 29
Finally, in an effort to engage a much
wider public audience in the issue of
sustainable production, scientists at IWF
are also developing learning materials
and experimental programs for people in
variousagegroups.Theaimistoestablish
a learning and teaching internet portal
which informs users abouttherisksand
opportunities of global production.
► A vision of sustainable production
AlltheresultsobtainedbyCRC1026are
fedintoaso-called‘demonstrator’:apart
virtual, part real mapping of a complete
production system based on sustainability
criteria.Thisvisionembodiesbothtechni-
cal innovations and a paradigm switch in
manufacturing industry which promotes
mutualexchangeofknowledgewhilealso
promoting cooperation in sustainability
issuesasacompetitiveadvantage.This
paradigm shift moves not just product
manufacturing but its associated responsi-
bilities and opportunities to the local level
anywhereintheworld.ProfessorSeliger
isconvincedthat,»Suchanunderstand-
ingofglobalworkorganizationandvalue
creation has the potential to bring about
a fundamental change in the way we
humanslivetogetheronthisplanet.We
have the opportunity to offer prosperity
to a great many more people – whilst at
the same time also consuming far fewer
resources than ever before through the
use of innovative production technolo-
gies.AndCRC1026islayingoneofthe
foundationsstones.«
Objectives set by CRC »Sustainable Manufacturing«
Bridgingthe Gap
Bridgingthe Gap to hungry markets
> 5 billion peopleFrom saturated markets
< 1 billion people
30 Interview
In February 2011, SAP AG, the world’s leading business software company,
officially founded its first Innovation Center in Potsdam. In summer 2013,
staff will be moving into the new building located on the banks of Lake
Jungfernsee. In close cooperation with the Hasso Plattner Institute for
Software Systems Engineering (HPI) and the HPI School of Design Thinking,
new collaboration models with partners and customers are applied at the
Innovation Center. Specific projects are also being run with other research
institutes in the Berlin-Brandenburg region. For instance, scientists at
Fraunhofer IPK are now collaborating with SAP in the field of Secure Mobile
Identification, one of the increasingly important challenges in information
technology. FUTUR talked with Cafer Tosun, managing director of the SAP
Innovation Center in Potsdam, about the center’s mission and future.
FUTUR: Mr.Tosun,inearly2011SAP
announcedtheestablishmentoftheSAP
InnovationCenterasthefirstofitskind
globally,hereinPotsdam.Thenewbuild-
ingisslatedforopeninginQ32013.What
issospecialaboutthisnewbuilding?
Cafer Tosun: Workingcloselywith
ProfessorKembelandhisteamatthe
d.schoolinStanford,weputmucheffort
intofiguringoutadesignthatwould
reflectbothourworkingstyleandour
projects.Oneofthekeyfeaturesisa
combination of concentration and col-
laboration spaces, allowing our employ-
ees to focus and interact when the need
arises.Itisimportantforustomaintain
suchdynamics.Communicationis
anotherkeyaspectofsuccessfulcollabo-
rationindistributedteams.Oneofour
staff members researched that topic in
hisdissertation.Andourstudentshave
alsoevaluateditinaspecialproject.In
effect–werefertothisasamarketplace
theory – we are going to set up a central
venue for people to exchange their
views.Wearethinkingaboutacentral
coffeecorner.
FUTUR: How does this affect the architec-
turaldesign?
Tosun: Flexibilityiscrucial.Concentration
andcollaborationspacesmustbekept
inbalance.Wehaveevengonesofaras
to use wheeled walls that can be moved
andfoldedasrequired.Thecollabora-
tion spaces are extremely transparent, as
lots of glass has been incorporated into
thedesign.Thebenefitistwofold–glass
acts as a sound barrier, but still allows
plenty of light into the collaboration and
concentrationspaces.Theentiresideof
thebuildingthatfacesLakeJungfernsee
isveryopenandbright.Sometimeswe
deal with small projects, sometimes with
big ones; sometimes a whole bunch of
peopleworktogether,sometimesitisjust
one individual – this is where the big chal-
lengeliesintermsofflexibility.
FUTUR:Whowillbeworkingthere?
Tosun:Weareplanningfor100full-time
staffmembersplus200studentswork-
ing in multidisciplinary teams, according
toDesignThinkingprinciples.Wetreat
students in exactly the same way as regular
staffmembers.Afterall,asdigitalnatives,
theyarenotjusttomorrow’susers;they
alsobuildtomorrow’ssoftware.Thatmakes
themextremelyimportantforusatSAP
andfortheentiresoftwareindustry.Their
communication structures are much more
networked.Socialmediaplatformslike
Facebook,Twitter&Coareanaturalpart
oftheirdailylives.
FUTUR:WhydidSAPchoosePotsdamas
the location for the Innovation Center?
Tosun:Oneoftheregion’smanyinteresting
facetsisthescientificandacademicland-
scape, with renowned research institutions
likeFraunhofer,anditsuniversitieswithover
140 000students.Thereisalsoagrowing
number of thriving startups with whom
we collaborate applying our in-memory
technologyplatformSAPHANA.SAPHANA
allows for new innovative solutions to ana-
lyze and process huge volumes of data at
lightningspeed.Thisisabreakthroughcon-
sidering the ever-increasing amounts of data
which are being produced in ever-shorter
times.Theglobaldatavolumeroughly
doublesevery18months.Theenormous
amountofdatathattheFraunhoferIPK
reconstruction team will process with its
From Silicon Valley to Silicon Sanssouci
Contact
SönkeMoosmann
Phone+493315509-1360
FUTUR1-3/2012 31
Director of the SAP Innovation Center Cafer Tosun
»Stasi-Schnipselmaschine«isjustoneex-
ample of an interesting application enabled
bySAPHANA’sin-memorytechnology.
FUTUR: In what other areas are you collabo-
ratingwithFraunhoferIPK?
Tosun: Secure Mobile Identity is one very
excitingproject.Onourside,wearevery
interested in integrating joint develop-
mentsintoourownproducts.Mobility
isastrategictopicforSAP.Moreand
more tablets, smartphones, laptops, and
ultrabooksarebeingpurchased,while
desktopsalesaredwindling.Itisatrend
that can be seen across nearly all indus-
tries.Anotherprojectwearecurrently
collaborating with the Charité hospital on
isthe»Oncolyzer«,whichisamobileap-
plication to help doctors and researchers
identify the best therapy for cancer pa-
tients,directlyatthepatient’sbedside.It
also puts a special focus on security and
dataprotection.Anotherchallengethat
really comes to the forefront with mobile
applicationsishowtoflexiblyadapt
security settings to any particular situa-
tion’sneeds.Mykids,forinstance,are
crazyabouttheiPad.Sowhentheywant
toworkorplaywithit,ithastobeboth
easyandsecure.Thesamethingapplies
when doctors handle highly sensitive
patientdata.However,thesecurityand
data protection requirements are much
higherinthelattercase.Inthiscontext,
wecangreatlybenefitfromtheresultsof
ourcollaborationwithFraunhoferIPK.
FUTUR: Why do you partner with
Fraunhofer?
Tosun: The answer to that is really simple:
Fraunhofer is a well established research
institutewithanexcellentreputation.
Andmanyoftheresultscomingoutof
Fraunhoferaretrulyground-breaking.
Thus, a partnership creates synergies for
bothSAPandFraunhofer,andthesewe
wanttouse!Wearealreadyseeingthese
effectsinourjointprojects.
FUTUR: What made you leave Silicon Valley
forSiliconSanssouci?
Tosun:Ilivedandworkedthereforeight
years.WhenIfirstmovedtotheUS,Iwas
fascinated by the enthusiasm and the spirit
to seize new opportunities and start off to
newhorizons.Start-upsweremushroom-
ing all over; people were developing busi-
nessideasandtalkingaboutthefutureof
theinternet.Icanstillrememberanevent
backin2002whenthethemeof»social
networks«croppedup.»LinkedIn«was
new at that time and people would have
long intense discussions about where the
journey would lead, whether it would be
acceptedorwhatcouldbedonewithit.
Now,Icanverymuchsensethesamekind
ofspirithere.Forinstance,wefrequently
meet with young entrepreneurs, develop
ideasandtrythemouttogether.Forme,
it is extremely encouraging to see that
acultureistakingrootinGermanythat
allows things to be tried out – a cul-
turethatalsopardonspossiblefailure.I
thinkthatthisgrowingmentalitycarries
enormouspotential.Whatweneedmore
of is venture capital and an even greater
readinesstotakerisks.Atthemoment,we
are sitting in the same building as Hasso-
Plattner-Ventureswhichlookatandinvest
inpromisingstart-ups.Ifwegetmoreof
that, we will be very well positioned in the
regionandinGermanyasawhole.Bythe
way,justlikeourcolleaguesinPaloAlto,
weheldaStart-upForumonAugust15th
inBerlin.Wewanttoworkcloselywith
the start-ups in the region and across Ger-
many, and build a bridge to Silicon Valley
bydoingso.
Interview by Steffen Pospischil
Profile
CaferTosun,SVP,isheadofthenewSAP
InnovationCenterinPotsdam.Heisalso
responsible for joint projects with the
HassoPlattnerInstituteinPotsdam.Tosun
hasbeenatSAPsince1993andhasheld
different development and consulting posi-
tionsatthecompanyinthattime.Healso
workedatSAPLabsinPaloAlto,Silicon
Valleyfor8years.Hestudiedcomputer
scienceandisacertifiedprojectmanagerat
StanfordUniversity.
32
SAP
SAPInnovationCenter–»Garage2.0«
Company Profile
– or in other words, anything that does
notfinditswaytothecustomerisnoin-
novation.Thisiswhyeveryprojectatthe
Innovation Center directly involves future
users,fromSAPandNon-SAPcustomers.
Highly professional, mainly young, IT ex-
pertstakethelatestandmostpromising
research trends in in-memory technol-
ogy, cloud computing and mobility, and
developsolutionswithandforusers.
While close cooperation with research
institutesliketheHassoPlattnerInstitute
for Software Systems Engineering, the
Fraunhofer-Gesellschaft,Berlin’suniversi-
ties, Stanford University and the Mas-
sachusetts Institute of Technology ensure
that the projects remain pitched on the
cutting edge of technology, customers
liketheCharitéhospitalandBigpoint
bringintheirownspecificknow-how,
and provide the grounding in local reality
that’sneeded.
TheSAPdevelopmentdepartmentisalso
involvedinprojectworkfromthevery
beginning.Onceaprototypehasbeen
evolved in this way and put through its
paces at the user (company), the baton
ispassedontothecolleaguesatSAP
development who transform it into a
market-readyproduct.
ThechoiceofthecityofPotsdamin»Sili-
conSanssouci«ispartoftheoverallcon-
cept:itsrichclusteroffirstclassresearch
institutions and companies, many within
walkingdistanceofoneanother,means
that the projects of the new Innovation
Centerwillfindtrulyfertilegroundhere.
Predefinedprocessesandfixeddevelop-
ment cycles with rigid deadlines are as
foreign to the mantra as an aversion to
takingonriskyprojects.Everyprojectis
different and that difference is recog-
nized and respected, even if the outcome
isuncertain.Thiswouldbecalled»artistic
freedom«inthecreativeindustrywhere
the Innovation Center is already engaged
in an on-going project with the Babels-
bergFilmstudios.
JustbylookingattheSAPInnovation
Center’snewbuilding–whoseground-
breakingceremonywasheldinOctober
2011–youcanseethatsomethingtotally
newistakingshape.Thefutureoffice
building of the Innovation Center is being
builtonthegroundsofaformerbarracks
ontheCampusJungfernsee.Whenit’s
completedin2013,thebuildingwilloffer
spacefor100fulltimeemployeesand200
students.Itwillnotbefancybutinspira-
tional and fostering creativity – the way a
Garage2.0should!
However,»backtotheroots«would
beaninadequatedescriptionofthefirst
SAPInnovationCenter’smission.Found-
edinPotsdamin2011,itratherseeksto
bring together the creativity and agility of
a garage startup with the expertise and
customerbaseofaworldmarketleader
inenterprisesoftware.»Combinedesir-
able,viableandfeasible«isthemission
Model of the new building for the SAP Innovation Center in Potsdam
Your contact
SAPInnovationCenter
SönkeMoosmann
Prof.-Dr.-Helmert-Str.2-3
14482Potsdam
Phone+493315509-1360
www.sap.com
Think of a garage and you might think of things like cars, garden tools,
stacks of firewood, or all kinds of old jumble. But in the IT industry the
word »garage« conjures up a totally different set of associations – things like
creativity innovation, pioneering spirit, and success. Even the big players in the
industry like Apple, HP and SAP started out from humble beginnings – just a
simple garage or in the case of SAP in 1972 a modest house in Weinheim.
33Events and Dates
Ecuadorian Minister visits PTZ
On15October2012,Prof.Uhlmann,executivedirectorof
FraunhoferIPK,welcomedtheEcuadorian»MinisterioCoordina-
dordeTalentoHumano,«AugustoEspinosa,totheProduction
TechnologyCenter(PTZ).Inhisaddress,Prof.Uhlmanninformed
theMinisterabouttheopportunitiesofferedbyFraunhoferIPK
forinnovationtransferabroad.Afterwards,Espinosaandhis
delegationweretakenonatourofthetestinggroundwherethe
Minister himself operated the dry ice blaster and could see with
hisowneyesjusthoweffectiveitwas.Atthefollowingpresenta-
tion of the Virtual Reality Cave, the Minister did not want to miss
theopportunitytomakehisowntrialrun.IntheApplicationCen-
terforMicroproductionTechnology(AMP),theair-conditioning
systemwasjustoneofthemanythingsthatexcitedkeeninterest:
it can regulate the temperature of the ultra-precision labora-
torywithaccuracyintherangeof±0,2°C.Prof.Uhlmannand
Minister Espinosa both underscored their interest in collaborating
togetherinthefuture.
A high ranking visitor from Ecuador: the Ministerio Coordinador de Talento Humano operates the dry ice blaster.
Your contact
Steffen Pospischil
Phone+493039006-140
On15March2012,H.E.JoséJoaquínChaverriSievert,Ambas-
sadoroftheRepublicofCostaRica,visitedFraunhoferIPK.He
waswelcomedbyDr.BertramNickolay,headoftheSecurity
Technologydepartment,whoalsoarrangedthevisit.Duringhis
visit Chaverri Sievert was particularly interested in the innovative
softwaresolutionscurrentlyunderdevelopmentatIPK.These
includethe»ePuzzler«programforthevirtualreconstructionof
documents shredded by the Stasi, the security apparatus of the
formerGDR,andthe»desCRY«und»SecureMobileIdentity
(SMI)«projects.desCRYisasoftwareforidentificationofchildpor-
nographyontheinternet.SMIenablessecureauthenticationofthe
usersofanenterprisecompanynetworkviamobileenddevices.
Your contact
Steffen Pospischil
Phone+493039006-140
[email protected] Chaverri Sievert (right) and Dr. Bertram Nickolay in the PTZ testing area
A Guest from Costa Rica
AmbassadorChaverriSievertatIPK
Events and Dates3434
BentoBox tried, tested and proven
Prototypecompletesfirsttestphasewithflyingcolors
IncooperationwiththelogisticsconsultantsLNC,FraunhoferIPK
hasdevisedthe»BentoBox«,aninnovativesolutionforinnercity
logistics.Thiscollectionstationforpackets,packagesandsmall
parcelspasseditsfirsttwomonthtrialruninBerlinwithflying
colors:85percentofourierdeliveryinthecatchmentareacould
bedonebybicyclesinsteadofvans.TheBentoBoxalsoenables
bundlingofdeliveryorders.Anditsdockingstationforsixsmall
containershelpstomakeurbanlogisticsprocessesmoresustain-
ableandmoreefficient.Itevenwithstoodtherigorsofthetradi-
tionalstresstestinthepeakpre-Christmasperiod,andalsogave
excellentresultsindealingwithexpressandovernightdeliveries.
The BentoBox is targeted at both logistics providers and business
andprivateendcustomers.Atthemomentitisbeingtestedin
Lyon,France,afterwhichitwillgotoTurin,Italy.
One of Messenger Transport + Logistik’s bicycle couriers demonstrates how the Bentobox is used.
2. International Conference MRO
23–24May2013
In terms of products and goods with high investment costs and
long lifecycles, MRO – maintenance, repair and overhaul – ac-
countsforalargepartofcompanyexpenditure.Aproduct’s
lifecycle also includes unexpected repairs and not just regular
schedulable maintenance, while an overhaul can not only restore
a product to its original condition but also incorporate improve-
ments that bring it into line with the latest technical and eco-
nomicdevelopments.MROprocessesmakeasignificantcontri-
butiontoconservingresourcesandenhancingenergyefficiency
whileatthesametimebringingtangibleeconomicbenefits.The
Conference offers an international cross-industry meeting point
forallcompanies,suppliersandcustomerswithastakeinMRO.
Itsobjectiveistoreflectoncurrentdevelopments,totapnew
potentialsandtopavethewaytoasuccessfulfuture.Leading
speakersfromindustryandsciencewillpresentinnovativecon-
cepts and strategies in:
– Products: MRO-compliant construction
– Concepts: MRO processes and IT
– Technologies:AdaptiveandflexibleMROsolutions
– ConditionMonitoring:IntelligentMROsystems.
Your contact
Dr.-Ing.MarkusRöhner
Phone+493039006-279
www.innovationscluster-mro.de
Your contact
Dipl.-Ing.WernerSchönewolf
Phone+493039006-145
FUTUR1-3/2012 35
13th International Conference EUSPEN
27–31May2013
Your contact
Dishi Phillips
Phone+441234754023
www.berlin2013.euspen.eu
The 13th conference and exhibition of the European Society for
Precision Engineering and Nanotechnology (euspen) will provide
aleadingforumforindustrialistsandacademicsaliketoreview
the best of world-wide industrial innovation, progressive research
andtechnologydevelopments.Itoffersinformationonthelatest
precision and ultra-precision developments, reports and discussion
on progress, and room for starting and continuing international
cooperationbetweenresearchersandindustrialists.Delegateswill
gain an insight of the precision engineering and nanotechnology
prioritiesofEurope’sleadingindustrialnation,Germany.With
thecountry’shighimportanceofenergygenerationandefficiency
in mind the special session topic of the 13th euspen conference
and exhibition will focus on precision engineering for the
advance ment of energy generation, renewable energy and energy
efficientsystems
PTK2013 Effective Factories – Knowledge, Tools, Value Creation
25–26September2013
The competiveness of manufacturing industry is increasingly
shapedbytheefficientuseofknowledgeandtools.Knowledge
andtoolsarekeyfactorswhichdeterminevaluecreationinpro-
duction.Showinghowimportantthecloseconnectionsbetween
knowledge,toolsandadded-valueareinthedesignofefficient
manufacturing plants is the goal of the Colloquium on Techni-
calProductionPTK2013.Howcanwesuccessfullydevelopand
manufactureglobalandregionalproductsinthefutureaswell?
Whatresourcesshallweneed?Howcanweachievesustainable
valuecreation?Directlyfollowingthe11thGlobalConference
Your contact
Prof.Dr.-Ing.JörgKrüger
Phone+493039006-183
www.effiziente-fabriken.de
on Sustainable Manufacturing, experts from industry and science
willbegivinganswerstosuchquestionsatPTK2013.Theywill
presentnewconceptsforhandlingknowledge,togetherwith
thetoolsandmethodsthattranslateknowledgeintoadded
value,andtheywillalsodiscussscenariosfortomorrow’sefficient
factory.Apartfromthetalksduringtheplenarysession,three
furthersessionsfocusedon»Technology«,»InformationTech-
nology«and»ManagementandOrganization«willexplorethe
interactionsofknowledge,toolsandvaluecreationfromtheirre-
spectiveperspectives.Furthermore,theColloquiumwillalsogive
youtheopportunitytoexploretheTechnicalProductionCenter’s
testing area and gain insights into our extensive range of research
and teaching programs, and to meet and exchange ideas with
internationalplayersatthetraditionalBerlinevening.
Engirneering – Product Design – Man
ufactu
ring
– Inform
ation- Communication Technologies – Resource
Man
agem
ent
– En
gin
eeri
ng –
Pro
duct
Design –
Engerneering – Product Design – Manufa
ctur
ing
– In
form
atio
n &
Com
mun
icatio
n Technologies – Resource M
anagement– En
gin
eering
Enrneering – Product Desig
n –
Man
ufa
ctu
ring
– In
form
ation & Communication Technologies – R
esource M
ana Engern
eering – product Design –
Man
ufac
turi
ng –
Info
rmation & Com
Eng
erneering – Product Design – Manufacturing – Informatio
n- C
omm
unic
atio
n T
ech
no
log
ies
– Re
sour
ce M
anag
ement – Engineering – Product Design – Manufactu
ring
–
Engirneerin
g – Pr
oduc
t des
ign
– m
anu
fact
urin
g –
info
rmat
ion & Communication Technologies – Resource Managem
ent – Eng
ineerin
g – Product Design – Manufacturing–
Eng
inee
rin
g –
Pro
duct
Des
ign – Manufacturing – Information & Com
munication
Techn
ologies – Resource Management– Engineering – pro
duct D
esig
n –
Eng
inee
ring
– Product Design – Manufacturing – In
form
ation & Communication Technolog
ies
–
Profile
Production Technology
CenterPTZBerlin
Your Contact at the PTZ Berlin
Corporate ManagementProf.Dr.-Ing.KaiMertinsPhone:+493039006-233,[email protected]
Virtual Product Creation,Industrial Information TechnologyProf.Dr.-Ing.RainerStarkPhone:[email protected]
Production Systems, Machine Tools and Manufacturing TechnologyProf.Dr.h.c.Dr.-Ing.EckartUhlmannPhone:[email protected]
Joining and Coating Technology (IPK)Prof.Dr.-Ing.MichaelRethmeierPhone:[email protected]
Joining and Coating Technology (IWF)Prof.Dr.-Ing.RainerStark(interim)Phone:[email protected]
Automation Technology,Industrial Automation TechnologyProf.Dr.-Ing.JörgKrügerPhone:[email protected]
Assembly Technology and Factory ManagementProf.Dr.-Ing.GüntherSeligerPhone:[email protected]
Quality Management, Quality ScienceProf.Dr.-Ing.RolandJochemPhone:[email protected]
Medical TechnologyProf.Dr.-Ing.ErwinKeevePhone:[email protected]
Fraunhofer Innovation Cluster
Maintenance, Repair and Overhaul (MRO) in Energy and TrafficDipl.-Ing.MarkusRöhnerPhone:[email protected]
Secure IdentityDipl.-Phys.ThorstenSyPhone:[email protected]
Fraunhofer Alliances
AdvanCer High-performance CeramicsTiagoBorsoiKleinM.Sc.Phone:[email protected]
Cleaning TechnologyDipl.-Ing.MartinBilzPhone:[email protected]
Traffic and TransportationDipl.-Ing.WernerSchönewolfPhone:[email protected]
Working Group
Tool Coatings and Cutting MaterialsFionaSammler,M.Eng.Sc.Phone:[email protected]
Ceramics MachiningDipl.-Ing.FlorianHeitmüllerPhone:[email protected]
Dry Ice BlastingDipl.-Ing.MartinBilzPhone:[email protected]
Microproduction Technology Dr.-Ing.DirkOberschmidtPhone:[email protected]
Berliner Runde (Machine Tools)Dipl.-Ing.ChristophKönigPhone:[email protected]
Competence Centers
Application CenterMicroproduction Technology (AMP)Dr.-Ing.DirkOberschmidtPhone:[email protected]
BenchmarkingDr.-Ing.HolgerKohlPhone:[email protected]
ElectromobilityDipl.-Ing.WernerSchönewolfPhone:[email protected]
Advanced TrainingClaudia EngelPhone:[email protected]
Methods-Time MeasurementDipl.-Ing.AleksandraPostawaPhone:[email protected]
Modeling Technological and Logistic Processes in Research and EducationDipl.-Ing.SylianosChiotellisM.Sc.Phone:[email protected]
PDM/PLMDr.-Ing.HaygazunHaykaPhone:[email protected]
Rapid PrototypingDipl.-Ing.(FH)KamillaKönig-UrbanPhone:[email protected]
SimulationDipl.-Ing.PavelGocevPhone:[email protected]
Self-Organising Production (SOPRO)Dipl.-Ing.EckhardHohwielerPhone:[email protected]
Scenarios for Product Development and Factory PlanningDipl.-Ing.MarcoEisenbergPhone:[email protected]
Virtual Reality Solution Center (VRSC)Dr.-Ing.JohannHabakukIsraelPhone:[email protected]
Reutilization of ResourcesDipl.-Ing.TimoFleschutzPhone:[email protected]
Knowledge ManagementDr.-Ing.Dipl.-Psych.InaKohlPhone:[email protected]
Dr.-Ing.MarkusWillPhone:[email protected]
Center for Innovative Product Creation (ZIP)Dr.-Ing.HaygazunHaykaPhone:[email protected]
The Production Technology Center
PTZ Berlin comprises of the Institute
for Machine Tools and Factory Man-
agement IWF of the Technical Uni-
versity of Berlin and the Fraunhofer
Institute for Production Systems and
Design Technology IPK. The PTZ de-
velops methods and technologies for
management, product development,
production processes, and design
of industrial manufacturing plants.
Furthermore, we also leverage our
proven expertise to engineer novel
applications in emerging fields such
as security, transport and medical
technology.
ThePTZisequallycommittedtomaking
its own contributions to application-
oriented basic research and to developing
new technologies in close collaboration
withindustry.ThePTZworkstogether
with its industry partners to transform ba-
sic innovations born in research projects
intofullyfunctionalapplications.
With the methods and techniques we
develop or improve, we offer our partners
comprehensive end-to-end support from
product development and fabrication
throughtoproductrecycling.Thisalso
includes the conception of means of
production and its integration in complex
production facilities, and innovation of
all corporate planning and controlling
processes.