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

[email protected]

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


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

[email protected]

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


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

[email protected]

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


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

[email protected]

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)


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

[email protected]

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.


► 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

[email protected]

Dipl.-Ing.MoritzChemnitz

Phone+493039006-127

[email protected]

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.


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

[email protected]

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


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

[email protected]

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

[email protected]

Dipl.-Ing.NikolausWintrich

Phone+493039006-252

[email protected]

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


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

[email protected]

Prof.Dr.h.c.Dr.-Ing.EckartUhlmann

Phone+493039006-100

[email protected]

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


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

[email protected]


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


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

[email protected]

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

[email protected]

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

[email protected]

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

[email protected]

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

[email protected]

www.innovationscluster-mro.de

Your contact

Dipl.-Ing.WernerSchönewolf

Phone+493039006-145

[email protected]

FUTUR1-3/2012 35

13th International Conference EUSPEN

27–31May2013

Your contact

Dishi Phillips

Phone+441234754023

[email protected]

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

[email protected]

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

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info

rmat

ion & Communication Technologies – Resource Managem

ent – Eng

ineerin

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Eng

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Pro

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Des

ign – Manufacturing – Information & Com

munication

Techn

ologies – Resource Management– Engineering – pro

duct D

esig

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Eng

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– 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.

Smart Production Technologies

Documents

production claudia engel

building of na

new ones

new products

dustrial training

brazil24 new bridges

silicon valley

eckartuhlmannco institute