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Software Development in Production Research
IPH – Institut für Integrierte ProduktionHannover gemeinnützige GmbH
(Institute of Integrated Production
Hannover Non-Profit Limited Company)
2IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ What IPH „is“ and „does“
■ Research Work
■ Discussion
Agenda
3IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Facts and figures –The Institut für Integrierte Produktion Hannover gGmbH
■ 1988: Foundation of the CIM factory Hanover gGmbH on the initiative of the professors Doege, Tönshoff and Wiendahl as a connecting link between research and industry
■ 1991: Move to the new institute building at the Marienwerder science park
■ 1993: Renaming to IPH - Institut für Integrierte Produktion Hannover gGmbH
■ 1998: Expansion of the institute building
■ Application-oriented research and development in the field of innovative industrial engineering as well as knowledge and technology transfer into economy
■ Combination of organizational and technological process chains through the co-operation of interdepartmental, interdisciplinary teams
■ 72 employees, including 28 engineers
■ Turnover of about 2,6 million € in 2009
4IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Industry, federal state of Lower Saxony, University
Central DepartmentDr.-Ing. Dipl.-Oec. Rouven Nickel
Dipl.-Wirtsch.-Ing. Dirk Altmann Dipl.-Wirtsch.-Ing. Henner Gärtner Dipl.-Ing. Malte Stonis
Advisory board
Production automation Logistics Process technology
Prof. Dr.-Ing. Bernd-Arno BehrensProf. Dr.-Ing. habil. Peter NyhuisProf. Dr.-Ing. Ludger Overmeyer
Managing Director
Partner
Organizational structure
5IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ Automotive industry and suppliers
■ Sheet metal forming industry
■ Mechanical engineering
■ Electronic industry
■ Aerospace industry
■ Forging industry
■ Mould and die production
Primary Industrial Sectors
6IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ Project coordinators
■ Public sponsors
■ Commercial sponsors
■ Others
Research Sponsors and Partners I
7IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©Meike Wiegand
Focus on XXL products
■ XXL products in Lower Saxony
■ Commercial and special-purpose vehicles:Volkswagen, Krone, Alstom, MAN
■ Wind turbines:Enercon, Bard Engineering, Nordex
■ Commercial airplanes:Airbus
■ Ships:Meyer Werft, Abeking & Rasmussen
■ Conveyor technique:ContiTech
■ Exports accounting of Lower Saxony in XXL branches:> 30 % (> 20,2 billion €)1
■ Exports accounting of XXL corporations:up to 90 %1 Source: Lower Saxony State Office for Statistics
8IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©Meike Wiegand
■ Today´s manufacturing of XXL products equals a manufactory.
■ The challenge is the industrialization of manufacturing XXL products.
• Simulation • Modelling
• Simulation
• Processautomation
• Material flowdesign
• Logistics management
• Networkmanagement
• Production and assembly processes
• Conditionmonitoring
• Serviceprocesses
• Decentralization
• Operatormodels
• Simulation
• Logistics processes
• Mastery ofcomplexity
• Dismantling /recovery
• Reconditioning
• Resourceefficiency
Innovationrequirements
(examples)
Conception Design Manufacturing / installation
Utilization RemovalXXL products
XXL products:Aim and need for action
9IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Res
earc
h T
opic
s
Cross Sectoral
Forging
Hydroforming
Hybrid Forming (bulk/sheet)
Research TopicsProcess Technology Department
Mu
lti-F
unc
tion
al T
ools
Pro
fitab
ility
of P
roce
ss C
ha
ins
Pro
cess
cha
in C
on
vers
ion
-Tec
hno
log
y
10IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Initial Situation
■ Conventional forging leads to flash proportions up to 45 %
■ Huge post-processing effort
Objectives
■ Reduction of production steps
■ Enhancement of energy and materialefficiency
■ Development of new tool concepts
Results
■ Omission of chipping through precision forging
■ Precision forging of two cylinder crankshaft
www.sfb489.uni-hannover.de
SFB489 Teilprojekt B2Innovative Tool Technologies
forging sequence
Source: ThyssenKrupp Gerlach
Technologie
Logistik
Präzisions-schmieden
IntegrierteWärme-
behandlung
Hartfein-bearbeitung
LogistischeKennlinien
Werkstoffefür das
Präzisionsschmieden
SimulationSchmieden
SimulationAbkühlung
Werkzeug-herstellung
AufmaßorientierteFeinpositionierung
PositionierungtechnologischerSchnittstellen
FlexibleLieferketten
Bauteil-prüfung
Geometrie-prüfung
ProzessketteTechnologie
Logistik
Präzisions-schmieden
IntegrierteWärme-
behandlung
Hartfein-bearbeitung
LogistischeKennlinien
Werkstoffefür das
Präzisionsschmieden
SimulationSchmieden
SimulationAbkühlung
Werkzeug-herstellung
AufmaßorientierteFeinpositionierung
PositionierungtechnologischerSchnittstellen
FlexibleLieferketten
Bauteil-prüfung
Geometrie-prüfung
Prozesskette
11IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Design of Production Networks
Res
earc
h T
opic
s
Save Material Flow in Production Networks
Cross Sectoral
Local Control of Production in Networks
Log
istic
s E
ffici
enc
y
Re
sou
rce
Ma
na
gem
en
t
……………
Research Topics Logistics Department
12IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
RFID-Chip AnschlüsseStrap
LOG
O
Strap-Rolle
Antenne
Falt-schachtel
Bogendruck inkl. Antennendruck
Vormontage Chip auf Strap
Strap-Montage
Erkennung Fälschung
Initial Situation
■ Imitations of pharmaceutical products harms health, economy and jobs
■ Bypassing longlasting and costly pharma research attracts imitators
■ Internet-pharmacies and re-imports demand new protective measures in distribution logistics
Objectives
■ Prevent the distribution of pharmceutical plagiarisms
■ RFID as electronic originality certificate for pharmaceutical-packaging
■ Detection and safeguarding of plagiarisms at latest at end-consumer
Results
■ Folding box with printed antenna and strap with pre-assembledRFID-chip
■ In pharmaceutical sector proven protection concept
www.ez-pharm.de
EZ-Pharm - Proving authenticity of folding boxes along the pharmaceutical supply chain
folding box
antenna
strapRFID-chip
connections
strap role
sheet fed and antenna printing
pre-assembly chip on strap
strap assemblyimitation detection
13IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Smart Systems101001100110
Distributed Systems
Wireless Communication
Sim
ula
tion
Te
chn
olo
gy
Bu
sin
ess
Pro
cess
De
sig
n
Sys
tem
Co
nsis
tenc
y
Sim
ula
tion
Research TopicsProduction Automation Department
Cross Sectoral
Res
earc
h T
opic
s
14IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Research Project Life-Cycle
Apply for funding
Carry out project
Utilize and enhance solution – identify new problems
Idea Approved funding
Project results
Generate new research ideas
New problem
[2 - 3 years]
15IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
€€
€
Industrial partners Public sponsorResearch institute
Problem / Idea
Theoretical solution
Prototype(software or physical)
Idea
Workforce
…
Test
Use
…
Supervise
Promote
…
Select
Fund
…
Software Development within Research Projects:
■ Creative – implementation of new ideas asks for new solutions
■ Independent – small team, few constraints (e. g. existing software environments)
■ Interactive – theory and software sometimes impact each other
■ …
■ Often implemented by students
Research Project
16IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ What IPH „is“ and „does“
■ Research Work
■ Discussion
Agenda
17IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Working at the IPH
■ First contact
■ Interesting Bachelor thesis
■ Chances at the IPH
■ Self-reliant working
■ Different projects
■ Responsibility
■ Positive aspects
■ Young team
■ Cooperative work atmosphere
■ Hannover
■ Tasks as an Software-Engineer
■ Develop software prototypes
■ Mentoring of students
18IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Service-Support through Semantic Web-Technologies
Initial Situation
■ For complex machines and devices failure resolution requires huge amount of know-how
■ Service employees spend much time on information retrieval (e. g. in failure-databases)
■ Simple information retrieval technologies do not bring forth high quality results in adequate time
Objectives
■ Support of service-hotlines during retrieval of similar service-cases through the utilization of semantic web-technologies
■ Implementation of a software prototype
Results
■ Algorithms for the retrieval of similar service-cases on the basis of meaning insteadof simple syntax (usage of ontologies)
■ Web-based database solution to ease service-case acquisition and retrieval
xxxx
(software engineer required)(software engineer required)
19IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
SemanticHelpline
■ History
■ 2004 – 2005: Erfahrungsbasierte Verknüpfung von Fehlerinformationen beim Betrieb von Werkzeugmaschinen zur Unterstützung von Service HotlinesExperience-Based linking of failure information at tool machines to support service-hotlines
■ Case documentation
■ Search with phonetic encoding
■ PHP / Oracle
■ 2007 – 2009: Semantic Web-Technologien zur Unterstützung des Service am Beispiel MaschinenbauService support through semantic web-technologies at the example of Mechanical Engineering
■ Semantic categorization with FIZ-Thesaurus
■ Java (Seam) / Oracle, PostgreSQL, MS SQL
■ 2009 – 2010: SemanticHelpline
■ Semantic search with FIZ-Thesaurus as DB & Wiktionary as DB
20IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
SemanticHelpline – Search
TextExtract Words
of Text
Search Word in Index
Word found?
Search Word in Thesaurus
List of additional
Words
no
Result
yes
21IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
SemanticHelpline – Thesaurus search
Word FIZ-Theasurus Wiktionary
Phon Code
clear text search clear text search
FIZ-Theasurusphonetic search Wiktionaryphonetic Search
synonyms,generic terms/ subtopics
synonyms,generic terms/ subtopics
verbs/ adjectives
synonyms,generic terms/ subtopics
synonyms,generic terms/ subtopics
verbs/ adjectives
Assign correct word
Assign correct word
22IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Intelligente Schnittstellen in wandlungsfähigen Lieferketten (ISI-WALK)
Initial Situation
■ Today‘s supply chains suffer from multiple obstacles.
■ Exemplary obstacles are rigidly automated conveying and storage systems as well as an insufficient consistency between physical and digital material logistics.
Objectives
■ The projects aims at the development of specific technologies and methods to realize an efficient and economic operation of versatile supply chains.
Results
■ positioning system based on optical technology
■ versatile warehouse management system
■ system for 3D object recognition
■ method for plannung and evaluation of versatility
www.isi-walk.de (work in progress)
Wandlungs-gerechte LVS (Ergebnis 3)
x
z
Optische Positions-bestimmung (Ergebnis 1)
y
3D-Objekt-erkennung (Ergebnis 2)
Lager
Lager
Bewertung und Planung der Wandlungsfähigkeit in Lieferketten (Ergebnis 4)
(electrical / software engineer required)(electrical / software engineer required)
23IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
(software engineer required)(software engineer required)
Automatisierte, CAD-basierte Kalkulation und Konstruktion (AutoKalK)
Initial Situation
■ Tool manufacturers must improve revenue and expense of their tender preparation
■ Production processes are to be planed flexibly in dependence of mould design and the trend of costs during the tool production is to be supervised
Objectives
■ The project’s aim is to develop a method for automated CAD model creation and CAD-based costing of tools
Results
■ Automated strip chart-based generation of CAD models
■ Automated and CAD-based costing and monitoring using artificial intelligence algorithms
AutoKalKautomated
mould designautomated
mould design
CAD-based, AI-basedcosting
CAD-based, AI-basedcosting
automatedcost controlautomated
cost control
production,assembly
finish part
strip chartautomated
tender preparationautomated
tender preparation
AutoKalKautomated
mould designautomated
mould design
CAD-based, AI-basedcosting
CAD-based, AI-basedcosting
automatedcost controlautomated
cost control
production,assembly
finish part
strip chartautomated
tender preparationautomated
tender preparation
24IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
(electrical / software engineer required)(electrical / software engineer required)Initial Situation
■ Over 67% of the total production costs of granite flaggings and boards are determined by the abrasive cutting process
■ Major energy and material costs are caused by high chipping ratios (cutting width / board width ~ 1)
Objectives
■ Development of a smart cutting tool that allows to reduce the cutting-wheel width as well as the risk of cut deviations
Results
■ Integration of measuring technology into the cutting-wheel for data acquisition (piezo-electric sensor) and preprocessing (chip)
■ Wireless data transfer to machine control
■ Reduction of cut deviations by automatedcontrol mechanisms
Smart Tools for Abrasive Cutting
25IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ www.iph-hannover.de Wissen Studium Newsletter
Student Jobs @ IPH
26IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
■ What IPH „is“ and „does“
■ Research Work
■ Discussion
Agenda
27IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Questions !?
■ Questions about IPH?
■ Questions about how to do a research project?
■ Questions about the introduced projects?
■ Other questions or remarks?
Discussion
28IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Contacts
Dipl.-Wirt.-Ing. Björn EilertAndreas Bruns Bachelor of ICT, NL
IPH – Institut für Integrierte Produktion Hannover gGmbHHollerithallee 6
30419 Hannover
Tel.: +49 511 279 76 - 228Fax: +49 511 279 76 - 888
E-Mail: [email protected]
www.iph-hannover.de
29IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH©19.05.2010Björn Eilert, Andreas Bruns
Ablauf der Semantischen Suche
Servicefall-Erfassung
Vorverarbeitung
Synonymsuche
Phonetische Codierung
Identifikation von ähnlichen Servicefällen
1Dokumentierte
Servicefälle
2 Relevanter Suchtext
3 Codierter Suchtext
4 Kategorisierte Begriffe
5Ergebnisliste mit
ähnlichen Servicefällen
Dokumentation der Servicefälle und Speicherung in der Datenbasis
Entfernung von Stoppwörtern, Umlauten, Satzzeichen, Abkürzungen, etc.
Grundformreduktion
Codierung des Textes zur Toleranz ggü. Rechtschreibfehlern
Ermittlung von SynonymenKategorisierung der Begriffe
Berechnung des Ähnlichkeitsmaßes für Servicefälle in der Datenbasis
Ausgbe der ähnlichen Servicefälle nach Relevanz
Fall-basis
Thesauri