Industrie 4.0

Research and Development at the Production Technology Center Berlin

FUTUR Vision Innovation Realization

Industrie 4.0

Decoupled from the Hardware Smart Shop Floor

Cloud-based Process Control

Where Production Is Self-organizing

INSTITUTE PRODUCTION SYSTEMS AND DESIGN TECHNOLOGY

INSTITUTE FOR MACHINE TOOLS A N D FA C T O RY M A N A G E M E N T T E C H N I S C H E U N I V E R S I TĂ„T B E R L I N

FUTUR 1 – 3/2014

Content

Editorial

Imprint FUTUR 1 – 3/2014 ISSN 1438-1125 Publisher Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Co-Publisher Prof. Dr.-Ing. Roland Jochem Prof. Dr.-Ing. Erwin Keeve Prof. Dr.-Ing. Holger Kohl Prof. Dr.-Ing. Jörg Krüger Prof. Dr.-Ing. Michael Rethmeier Prof. Dr.-Ing. Günther Seliger Prof. Dr.-Ing. Rainer Stark

­Fraunhofer Institute for Production Systems and Design Technology IPK Institute for Machine Tools and Factory Management IWF, TU Berlin Editor-in-chief Steffen Pospischil

Compilation, Layout and Production Claudia Engel, Ismaël Sanou Contact Fraunhofer Institute for Production Systems and Design Technology IPK Director Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Pascalstrasse 8-9 10587 Berlin Phone +49 30 39006-140 Fax +49 30 39006-392 info@ipk.fraunhofer.de http://www.ipk.fraunhofer.de

04

Decoupled from the hardware – cloud-based process control

06

The smart shop floor – where production is self-organizing

08

Additive manufacturing technologies – an alternative for product manufacturing in the digital age

10

Intelligent planning – cuts aircraft maintenance time

12

HEPHESTOS – a technology platform for robot-assisted machining

14

Ensuring process stability – milling with industrial robots

16

More functions for more efficiency – a new turning tool design

18

Precision laser – measurement of wear during machining

Education Special

20

GPE – International Master’s Program in Manufacturing and Renewable Technologies

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann

Digital media have long shaped our everyday

naturally for robotics solutions for factories.

Last but not least, we invite you to take a look

lives and are now increasingly transforming

Our expertise in this field ranges from inno-

at our special section on education included

classical forms of production technology, too.

vative kinematics systems with novel drive

in this magazine. Both our institutes have a

Industrie 4.0 and its vision of the intelligent

and control technology to overarching pro-

long tradition not only in basic and applied

networked factory of the future is a major

cess control engineering and technology that

research, but also in university-level teaching.

talking point as mobile technologies like

supports human operators. But our robotics

As an institute of the Technische Universität

cloud computing are revolutionizing indus-

solutions are not just for industrial produc-

Berlin, IWF instructs some 200 students a

trial processes. With embedded systems,

tion alone; we engineer them for the fields

year in mechanical engineering. Its Master’s

components and machines can now talk to

of medicine and rehabilitation as well. Our

degree course on Global Production Engi-

one another and self-optimize, self-configure

medical technologies help make surgical

neering teaches students from all over the

22

GPEM – Master of Science in Global Production Engineering and Management

24

MSE – Degree Program on Mechatronic Systems Engineering

26

One Hundred Years of History – a German University in Turkey with a Focus on Applied Science, Interview with Rita Süssmuth

and self-diagnose, providing intelligent sup-

interventions safer and more efficient, and

world the skills needed to cope with the chal-

port for workers in their increasingly com-

with »CareJack« we showcase a kind of intel-

lenges of the global industrial society. Due

plex decision-making. Today’s centrally orga-

ligent jacket that supports caregivers in their

to its success, GPE has become a role model

28

MUREE – Bachelor Program on Renewable Energies

nized enterprise is turning into a decentralized

physically demanding work.

for other international degree programs we

29

Teaching sustainable development worldwide

32

The operating theatre route planer – instrument navigation for minimally invasive surgery

Printed by Ruksaldruck GmbH + Co. KG Photos Adam Opel AG: 1, 7 Berliner Zentrum für Mechatronische Medizintechnik BZMM: 32 Dan Bondy: 47 Fraunhofer IPK / S. Pospischil: 41 Fraunhofer IZM: 34 Hilmi Güner: 24 José Paulo Lacerda/CNI: 42 Schaudt Mikrosa: 40 ZhongDe Metal: 43

Dear Readers,

34

More power for the personnel – an active jacket for caregiving support

36

Reissued – the »Intellecutal capital statement – MADE IN GERMANY« toolbox and user guide

38

Smart robotics – solutions for a flexible production, Interview with Stefano Ocleppo, Comau Germany

40 41 42

Company Profile: Schaudt Mikrosa Machine Portrait: Selective Laser Melting Events and Dates

© Fraunhofer IPK Reprint, also in extracts, only with complete references and after consultation with the editors.

Please forward a copy.

dynamically controlled factory of the future

established recently in Vietnam and Turkey.

whose production is defined by individual-

Yet all the hype and enthusiasm generated

Whether they focus on production engineer-

ity, flexibility and rapidity. Industrie 4.0 is no

by future trends such as Industrie 4.0, cloud

ing and management, mechatronic systems

longer some futuristic vision, but very much

computing, electromobility and resource

engineering or renewable energies, they all

on the march as you can read in this latest

efficiency should never make us lose sight

impart sound technical expertise, entrepre-

edition of FUTUR magazine.

of something as essential as basic technol-

neurial and management skills, as well as inter-

ogy for manufacturing products. This is why

cultural competencies. What's more, their inter-

Perhaps you remember the False Maria,

development and optimization of technolo-

national pool of lecturers composed of leading

Robby or C-3PO and R2-D2? If robots first

gies and tools for machining and the qualifi-

academics and senior industry representatives

appeared as science fiction in books and

cation of ground-breaking concepts for cut-

as well as the involvement of renown global

films nearly one hundred years ago, today

ting materials and tools and their integration

companies in internship programs provide a

they are an essential part of our work and

in industrial process chains are among the

unique link between theory and practice.

lives. From assembly lines to medicine and

cornerstones of our work as a research insti-

health care they can be found everywhere

tute for production technology. With the

performing useful work for people. We offer

»evo.T « we have developed a multi-func-

you a look at what is going on behind the

tional turning tool with improved vibration

scenes and show you what hot topics we are

and temperature behavior, closed internal

currently researching and developing in the

cooling and integrated condition monitor-

field of robotics. As an institute focused on

ing that enables much more efficient dry pro-

production technology our prime concern is

cessing of titanium alloys.

We hope you enjoy this magazine!

5

With best wishes for a successful New Year,

Eckart Uhlmann

3

4

Research and Development

FUTUR 1 – 3/2014

Industrie 4.0

Decoupled from the Hardware

The advantages of cloud-based control at a glance

Cloud-based Process Control

–– Greater independence of control process from hardware. This results in longer ser-

The third Industrial Revolution that took place in the 1970s and 80s was based on

vice life for control software and higher

»Computer Integrated Manufacturing«, the linkage of machines and computers.

investment security.

The Production Technology Center in Berlin was a key proponent of this change,

–– Flexible allocation of computing power in

and the control systems it developed for machine tools and robotics paved the

CPU-intensive processes such as complex

way for factory automation. The collaborative research project pICASSO in which

geometry calculations and sensor data

Fraunhofer IPK and the Institute for Machine Tools and Factory Management

processing.

IWF at the TU Berlin are taking part, is now raising these developments to the

Allocation of standard control modules between cloud and robot

–– Higher security for overall factory control

level of the fourth Industrial Revolution by using cloud technology to decouple

with private clouds than in decentralized

software control functionality from the hardware. This will lead to a fundamental

control systems. Optional cloud integra-

transformation in the IT architecture of future factories.

tion of legacy systems – old control units whose operating systems can no longer be given security updates.

►►Networked structures

software which used to depend on specific

allocated in a few seconds – for instance

The cloud-based control opens the way

Ever since the 1980s the IT structure of fac-

computer or control platforms is now sepa-

between the CPU-intensive processes of the

to upgrading or retrofitting high-quality

tories has been ordered hierarchically from

rated from it via virtual machines and trans-

five-axis interpolation of a milling machine

machines and equipment whose control

The cloud-based approach defines numer-

cloud-based control functionalities.

field level to the level of factory control.

ferred to the cloud.

or the complex axis control of cooperating

systems are outdated. The main challenge

ous interfaces in the control modules. Con-

–– Streamlined communication interfaces

robots. Consequently, a much more effi-

here is meeting the stringent real-time

solidated in the pICASSO platform, access

of machines and equipment instead

►►Potential for factory control

cient use of available computing power

requirements set by state of the art machine

to these interfaces is opened so that value-

of heterogeneous communication struc-

vidual components – from computer numeri-

In a multitude of ways transfer of control

can be made than was possible with the

and robot control systems. pICASSO has

added services find their way in the plat-

cal control CNC and robot control RC to

functions to the cloud opens up a whole

older, purely decentralized control systems

adopted the approach of virtualizing less

form in terms of Apps. Application scenar-

Cloud technologies now make it possible to disengage these hierarchies and link up indi-

►►Versatile funtionality through value-added services

–– Simplified upgrading and retrofitting of outdated machines with state of the art

tures and protocols.

–– Higher energy efficiency through

manufacturing execution systems MES and

new dimension of flexibility. First off all, the

for individual machines and robots. At the

time-critical processes in a first stage and

ios range from a comprehensive series of

enterprise resource planning ERP – in flexible

cloud mechanism »rapid elasticity« enables

same time, further gains in flexibility are

mapping the hard real-time requirements

analytical tools and extended programming

networks. The core of this new approach is

the flexible and mostly automatic distribu-

given when – with adequate computing

of the closed loops in a trunk control.

the virtualization of systems in which soft-

tion of computing capacity. This means that

power – any number of virtual machine con-

ware functionality is decoupled from its spe-

the computing power of a whole group of

trols VNC or virtual robot controls VRC can

►►Reducing security risks

flows. Furthermore, modularization on a

(e.g. simulation, process modeling, visual-

cific computer hardware. In other words,

processor cores in a »private cloud« can be

be generated.

The pICASSO concept focuses on providing

common platform also streamlines configu-

ization, man-machine interfaces, program-

full computing capacity as a »private cloud«

ration and simplifies interaction between

ming) via the app concept.

within the factory. There are a number of

individual modules.

Ultra flexible networked factory control through control modules as services in the cloud

techniques to new possibilities for the visualization and simulation of process work-

virtualization.

–– Reduction of standby use through flexible allocation of computing power.

–– Easy connectability to value-added services

reasons why this offers a much higher level

The pICASSO project is funded by the Federal

of IT security than the decentralized con-

Ministry of Education and Research BMBF within

trol systems used thus far which come with

the framework program »Research for Tomor-

open USB-Ports or insufficiently secured

row’s Production« and is supervised by the Proj-

network access, both exposing various

ect Management Agency Karlsruhe PTKA.

weaknesses. The possibility of virtualizing older PC-based control units and integrating them in the cloud also reduces those IT security risks associated with the use of

Your contact

outdated versions of the operating system.

Moritz Chemnitz Phone: +49 30 39006-127 moritz.chemnitz@ipk.fraunhofer.de

Gerhard Schreck Phone: +49 30 39006-152 gerhard.schreck@ipk.fraunhofer.de www.projekt-picasso.de

5

6

Research and Development

FUTUR 1 – 3/2014

Industrie 4.0

The Smart Shop Floor Where Production Is Self-organizing The typical production line for today’s mass production is built of a number of specific components. Yet with increasing diversity in the range of manufactured products, such rigid production systems are now straining at their limits – particularly in terms of their ability to respond quickly, their workloads and their ability to meet delivery deadlines. In the »IWEPRO – Intelligent Cooperation and Networking for Shop Floor Production« project, partners from science and industry are now designing innovative production concepts to enable smart shop floor manufacturing with decentralized production control. They are engineering solutions with which intelligent networked products, production machines, transport systems and manufacturing resources can communicate with one another and cooperate with workers by adapting to particular tasks and situations.

►►Intelligent networking

all the employees and resources involved

Automobile makers and other manufac-

and needed in the production process. This

turing companies are increasingly turning

means that in future workers will be able to

The scenario for future shop floor manu-

to new technologies for everything from

make decisions in response to specific situ-

facturing with intelligent communicating

decentralized control systems to self-orga-

ations. What’s more, smart shop floor pro-

components is conceived and modeled on

duction with autonomously acting agents,

►►Self-organizing manufacturing

nizing product-driven manufacturing. They

duction also promotes the foresighted man-

the parameters of a limited production area.

and to elucidate the advantage of flexible

The model character of this research project

expect them to deliver optimized production

agement and timely delivery of the resources

Simulations are used to investigate the inter-

over centrally controlled rigid production

means that the results to be expected from

Project Partners

processes, especially with regard to small

needed for upcoming production runs.

play of a decentralized distributed produc-

structures. In pursuit of these goals, IPK

it will have a much broader relevance and

–– Adam Opel AG, Rüsselsheim

tion control unit with equipment compo-

scientists are building a reference archi-

can be applied equally to other system pro-

–– SimPlan AG, Maintal

made products. The bar on such intelligent

►►Cyber-physical production systems

nents as well as the behavior of the overall

tecture and implementing and testing an

viders and sectors manufacturing highly vari-

–– flexis AG, Stuttgart

networked production systems is set very

Against this backdrop partners in the

system. To this end the project is develop-

agent framework for self-organizing shop

able high quality products in the metal

–– TAGnology Systems GmbH, Karlsruhe

high: they should be ultra flexible, capable

IWEPRO project are developing solutions

ing modeling and simulation tools and an

floor control. Alongside generic agents for

working industry and subcontractors in the

–– SAFELOG GmbH, Kirchheim

batch production and varying individually

►►The automobile manufacturing scenario A visionary concept – what work in a networked shop floor production environment could look like.

of controlling adaptive process chains and

with which products, production machines,

adaptive production management system

standard tasks, the Fraunhofer experts are

mechanical engineering industry, the vehicle

–– DMG Electronics GmbH, Pfronten

capable of responding to unforeseen circum-

transport systems and production resources

together with an appropriate communica-

also designing methods that will allow the

construction industry and the medical tech-

–– Soziologisches Forschungsinstitut

stances. To meet such high requirements

can exchange information on contract

tion infrastructure, knowledge-based self-

practical knowledge of shop floor person-

nology sector. Self-organizing shop floor

they need software solutions that can link

orders and production among themselves

learning shop floor control, autonomous

nel to be pooled and factored into a knowl-

manufacturing could also potentially be suc-

Göttingen SOFI e.V., Göttingen –– Fraunhofer IPK, Berlin

the virtual world with real objects, send job

and adapt to tasks and situation in coopera-

decentralized software agents, an interoper-

edge-based self-learning shop floor control.

cessfully transferred to a broad range of

data to smart mobile objects, and synchro-

tion with workers. The key element here is

able machine tool and intelligent appliances.

The prototype for the realization and dem-

small and medium-sized manufactur-

nize decentralized control and monitoring

the cyber-physical production system CPPS

This development work is companioned by

onstration of the new self-organizing shop

ing companies.

functions.

which synchronizes centralized and decen-

research in the sociology of work in order

floor production model will be given in an

BMBF within the framework program

The IWEPRO project is funded by the Federal Ministry of Education and Research

tralized control and monitoring functions

to ensure that from the very beginning both

application scenario for the manufacturing

»Research for Tomorrow’s Production«

The IWEPRO research project is focused on

by linkage of the ICT world with real-world

management and the production work-

of highly varied automobile components

and is supervised by the Project Management

the shop floor production level, as this is the

objects. In addition, the project also delivers

force are involved in the design of a work-

involving the participation of the shop floor

Agency Karlsruhe PTKA.

level on which flexible production structures

methodological support for the participative

place that takes account of human require-

personnel. A migration concept is being

with autonomously acting components can

design and roll-out of solutions. For instance,

ments, and that both groups are integrated

developed for this scenario with graduated

offer significant advantages over centrally

if shop floor operatives are to be efficiently

smoothly as actors in the production system

decentralized intelligence and networking of

controlled rigid structures. Smart shop floor

integrated in planning, controlling and moni-

as well as to prepare the ground for pro-

the subsystem which holistically covers the

Your contact

production consists of decentralized struc-

toring, they need to be prepared for the new

fessional qualification programs. Fraunhofer

technology, business process and qualifica-

Eckhard Hohwieler

tures with small closed loops and is built

system and the range of highly flexible tasks

IPK’s role in the project is to push forward

tion in the form of an extendible shell model

Phone: +49 30 39006-121

on efficient results-oriented communica-

and assignments it brings with it.

development of individual components in

with products, machines, tools, appliances

eckhard.hohwieler@ipk.fraunhofer.de

existing approaches to self-organizing pro-

and transport system.

tion and networked cooperation between

www.projekt-iwepro.de

7

8

Research and Development

FUTUR 1 – 3/2014

Industrie 4.0

Additive Manufacturing Technologies An Alternative for Product Manufacturing in the Digital Age Additive manufacturing technologies such as 3D printing and laser melting are key technologies for needs-oriented efficient production systems that can respond flexibly to changing customer demand. With the support of the Federal Ministry of Education and Research BMBF, Fraunhofer IPK is honing these technologies and their associated processes for across-the-board use in industry.

►►A great potential still to be fully realized

with process monitoring and state detec-

before the potential of additive techniques

tion systems in order to ensure robust and

in terms of material and energy efficiency

Companies that want their products to stay

defect-free production. Then, once devel-

can be realized. These include improved

competitive in the future need flexible and

oped, the process chains must be adapted

data consistency, more reliable manufac-

highly efficient production systems – sys-

for a broad variety of application scenarios.

turing parameters and a robust process

tems that do not just take account of ecolog-

Their tremendous flexibility which makes it

chain for the fabrication of conditioned and

ical aspects and the scarcity of resources, but

possible for them to produce even the most

functionalized products. These are the goals

that can also respond to increasing differen-

complex structures makes additive manufac-

addressed by Fraunhofer IPK in association

tiation in customer demand which leads to

turing technologies like laser melting highly

with the Fraunhofer institutes IWS, IWU and

a higher number of variations with smaller

attractive to a wide range of branches. At

MEOZ in a major research project. Scientists

batch lots for each variant. In this regard

present stainless steel, tool steel, titanium,

working on the project »Additive Genera-

generative manufacturing holds an enor-

aluminide, nickel-based alloys and plas-

tive Manufacturing – the 3D Revolution in

mous potential – yet there is much need for

tics can all be processed. Yet the variants

Product Manufacturing for the Digital Age

improvement before it can be successfully

in process stability additive technologies

– AGENT 3D« are developing generative pro-

applied to industrial use. First of all, flexible

have thus far displayed make them unsuit-

cess chains for the fields of turbo machin-

A lifecycle-oriented value-added chain for the deployment of additive manufacturing technologies

►►Added value for enterprise

Additive Generative Manufacturing –

Even today it is apparent that the industri-

With this collaborative research project, the

The 3D Revolution in Product Manufactu-

alization of additive manufacturing technol-

consortium of Fraunhofer Institutes and their

ring for the Digital Age AGENT 3D

introduction of novel additive techniques.

process chains need to be developed built

able for use in industrial serial production.

ery, aviation, tool making and the consumer

ogies means that the whole value-added

partners from the SME sector are seeking

Duration: 2013 to 2020

on generative technologies and equipped

A large number of criteria need to be met

goods industry which pay attention to the

chain must be taken into consideration.

to drive forward integration of additive man-

Partners: 40 partners including 25 SMEs

whole product lifecycle, especially the areas

This is why the scientists engaged in the

ufacturing technologies in industrial produc-

and 11 research institutions

of design, factory planning, production qual-

project have a two-fold focus: on funda-

tion. This will help companies to optimally

Financing: BMBF Twenty20 – Partnership for

ity management and recycling. In this way

mental research and on application-related

respond to short innovation cycles and

Innovation

the consortium of Fraunhofer institutes is

concepts for tool machines, multi-material

reduced development times and thus stay

Total budget: 45 million euros

making a substantial contribution to the

systems, adaptive process chains and the

competitive in the long run. In particular,

Coordination: Fraunhofer IWS

Federal Ministry of Education and Research’s

qualification of robust and stable technol-

with the support of the project consortium,

Partners of Subproject AGENT 3D:

»Twenty20 – Partnership for Innovation«

ogies. In terms of integration of additive

SMEs in the Germany’s new Länder are

Fraunhofer Institute for Material and Beam

research project within whose framework

manufacturing systems in flexible produc-

given the opportunity to rapidly assume a

Technology IWS, Dresden

tion structures, engineers at Fraunhofer IPK

leading role on the market and position

Fraunhofer Institute for Machine Tools and

are following the aim of establishing certifi-

themselves as first suppliers for major cor-

Forming Technology IWU, Chemnitz

A turbocharger with integrated lightweight grid structures

the AGENT 30 project is funded.

►►A strategic technological roadmap

able production systems. On the technologi-

porations. They also benefit from the expe-

Fraunhofer Center for Central and Eastern

The project’s major concern is to draw up a

cal level, this means that peripheral systems

rience and know-how of the ­Fraunhofer

Europe MEOZ, Leipzig

scientific, technical, organizational and eco-

for state detection and monitoring must

innovation clusters »Maintenance, Repair

Fraunhofer Institute for Production Systems

nomic roadmap for the widespread indus-

be integrated in additive process chains to

and Overhaul MRO« und »Life Cycle

and Design Technology IPK, Berlin

trial use of 3D technologies. In a first step

enable consistent end-to-end process con-

Engineering LCE« which develop holistic

Fraunhofer experts draw up a needs analysis

trol and thus effective quality management.

solutions for the use of energy and re-

of enterprise-side requirements and assess

source-efficient technologies in energy

the potential of various additive technolo-

and transport.

Your contact

gies for a broad spectrum of application sce-

André Bergmann

narios. This forms the basis on which they

Phone: +49 30 39006-107

build a strategy for the development and

andre.bergmann@ipk.fraunhofer.de

9

10

Research and Development

FUTUR 1 – 3/2014

Industrie 4.0 Control Level

Intelligent Planning

Alert Management Capacity Planning Service Management Reliability Management

Cuts Aircraft Maintenance Time Direct Distribution of Assignments between Aircraft, Mechanic and Parts Logistic

Knowing that their planes are available when and where needed is a decisive factor in the competitive global market of airline companies. Apart from issues of maintenance, repair and overhaul MRO, factors like inadequate planning and control also limit the availability of aircraft fleets. Use of decentralized intelli-

Automatic Distribution and Control

gence with aircraft, spare parts and tools can drastically shorten process chains and save operators much time and money.

Identifying Demand for MRO

unplanned

planned

possible reduction of their fleet by five air-

be used to shorten and streamline the plan-

craft which – given average leasing costs of

ning processes for maintenance and control.

around 300,000 euros per aircraft a month –

Electronic components already in use like

represents a pretty substantial saving.

EFB that support such a procedure would

Decentralized control with CPS components

continue to do so only more efficiently in

Planning / Control

Distribution Changes Provide Tools and Spare Parts

MRO Site

Mechanic

Maintenance/Repair Sequential MRO processes make for lost time and fewer flights

►►Decentralized intelligence for

their extended versions.

located in Munich and its loading and trans-

agency in the planning and controlling. This

port from Munich to Berlin on a scheduled

drastically reduces the lengthy grounding

In association with airberlin technik,

►►New planning strategies

flight is planned and authorized. The soft-

times needed for major checks and ensures a much more profitable use of aircraft.

MRO planning and control Fraunhofer IPK has evolved a concept

These technologies open the way to new

ware agents also take care to ensure that

whereby individual MRO jobs are directly

planning scenarios. For instance, if the need

the tool arrives on time for the maintenance

assigned to the personnel who will carry

for a particular repair is identified on a flight

slot at the specified maintenance station.

them out. The assignments are organized

from Palma de Mallorca to Berlin, the aircraft

Furthermore, this procedure can also be

automatically, either through cyber-physical

itself will determine in real-time that even

deployed to allocate a large part of major

systems CPS or existing electronic compo-

though the technician for this type of aircraft

MRO checks lasting a week or more across

nents like the electronic flight bag system

and the spare part needed are available in

day-to-day operations. As soon as a time

EFB. CPS are tiny end devices with memory

Berlin, the right kind of tool is lacking. In

window opens for an aircraft on the ground,

and processor units, sensors and position-

direct negotiation between the software

possible procedures are negotiated and allo-

finding mechanisms that can communicate

agents themselves, the right kind of tool is

cated without the need for any human

with one another and the central system.

Basic capacity planning, monitoring and

►►Tedious planning

sized German air carrier changes the routes

escalation management are carried out cen-

of about ten flights a day at very short notice.

trally for all aircraft. Additionally, spare parts

The planning and monitoring of aircraft

The upshot is that specially qualified tech-

and tools are equipped with CPS and after

maintenance and overhaul involves a

nicians sit at the maintenance station with

self-organized negotiations with the aircraft

and controlling processes

number of partners working together in a

expensive spare parts and tools waiting for

can be automatically assigned MRO work.

sequence of process stages. First of all the

a plane that never appears because it is in

Such a system streamlines the workflow,

need for MRO is assessed at central main-

a quite different place. And if an expensive

reduces the number of administrative steps

tenance control and a time slot is allocated

replacement flight cannot be found and the

and means that technicians can now be

for the maintenance station depending on

maintenance work is postponed to a later

commissioned from the aircraft directly and

the flight plan and the number of avail-

date, the plane must stay grounded and

in real-time and supported in their work by

able technicians, tools and spare parts. If

the connecting flight is lost. Even though

integrated scheduling and provision of spare

one of these stages does not function per-

computer-assisted, today’s procedures are

parts and tools (e.g. ground support equip-

fectly, the whole procedure must be gone

still not able to cope adequately and rapidly

ment) and by a fault tree system tailored to

through again from the beginning. This is

with last minute changes. Aviation experts

the aircraft. This raises the responsiveness

particularly problematic when the required

believe that there is room for improving the

of the operational personnel, enhances effi-

work has to be completed shortly before the

availability of aircraft by around three per-

cient use of the maintenance slot and dem-

next flight. For instance, a typical medium-

cent. For an air carrier this translates into a

onstrates how decentralized intelligence can

The system architecture of the new MRO concept

Escalation Management

Monitoring

Capacity Planning

Resource Planning Vehicles

Communication Bus Wireless, XML

Project Partners –– airberlin technik GmbH

Logbook with Maintenance Plan Wireless or Wire

Vehicle Sensors

eGrain

Spare Part

eGrain

Mobile Device

Tool

–– Fraunhofer IPK, Berlin

Your contact

Mechanic

Dr.-Ing. Thomas Knothe Phone: +49 30 39006-195 thomas.knothe@ipk.fraunhofer.de

11

12

Research and Development

FUTUR 1 – 3/2014

Robotics

HEPHESTOS A Technology Platform for Robot-assisted Machining September 2012 saw the start of the European collaborative research project »Hard Material Small-Batch Industrial Machining Robot – HEPHESTOS« under the general management of Fraunhofer IPK. Terminating in 2015, this project brings together research partners, robot and sensor manufacturers, planning and simulation system developers and system integrators to develop control

C4G Open Controller

Robot Kinematics

Process

procedures and planning tools for the robot-assisted machining of hard materials. Standard industrial robots and open system interfaces are used that allow for application-oriented adaption and extension. The aim of the project is to develop a technology platform with open software tools and robot systems that is suitable for small-batch production and that meets the needs of companies in the SME sector.

►►Robots to replace machine tools Attempts to use industrial robots in the

Open Control System

Robot Signature-Based Planning & Programming

Control - Language Level - Servo Level External Control Computer with IPK Modules

same way as tool machines very soon reach

The development platform at Fraunhofer IPK

their limits – particularly when it comes to the machining of hard materials. Tool

mapping and robot control. Sensors for the

compliance. The aim is to develop novel

HEPHESTOS Project Partners

machines are optimized for such machin-

manual control and online programming of

adaptive process strategies and to ensure

–– Comau, Italy

ing processes and are characterized by their

robots are also being developed. Comple-

system stability in robot process interaction.

–– EasyRob, Germany

mentary to CAD/CAM-based programming

Real-time corrections for improvement in

–– Fraunhofer IPK, Germany, project

the »Human-Machine Interface« module

the positioning and machining accuracy as

is concerned with manual sensor-assisted

realized in robot control research play a vital

–– G-Robots, Hungary

programming techniques and their integra-

role here with consideration given to such

–– JOT Automation Oy – MAG, Finland

high accuracy and rigidity. Industrial robots,

Human-Assisted Programming

on the other hand, put the accent on high flexibility and universally deployable low-

Low-Cost Sensory Systems

cost kinetic structures. Yet robots also have

coordination

clear disadvantages, especially in terms of

tion in the workflow. Supported by multi-

factors as joint elasticity, machining force

–– ME Messsysteme, Germany

their lack of stiffness and positioning accu-

media input devices, work here is focused

and changes in the rotational direction of

–– Universidad Politecnica de Madrid –

on developing economically viable program-

individual axes. For development and test-

ming techniques especially for small batch

ing of the techniques Fraunhofer IPK has

–– Universitet i Agder – UiA, Norway

built its own development platform which

now features in numerous robot cells. It is

The HEPHESTOS project is funded by the

Advanced Control Algorithms

racy. At the same time improvement of their system characteristics through hardware solutions such as reinforced mechanics or additional measurement systems brings

The R&D modules in the HEPHESTOS project

and single parts production.

quality should be given through a combina-

for performance of what is known as robot

higher costs with it and thus limits the field

tion of techniques and process chains for

signature-based planning and program-

of application. Against this background the

robotic machining, e.g. milling, grinding

ming. Examples of this are consideration of

HEPHESTOS project is investigating currently

and polishing.

configuration-dependent robot rigidity and the computation of path corrections. The

available standard industrial robots and the

►►Robot cells for large-scale

UPM, Spain

based on the Comau C4G Open Robot Con-

European Community‘s Seventh Frame-

troller whose open real-time interfaces on

work Programme (FP7/2007-2013) Project

To test the HEPHESTOS technology platform

various control levels – with up to a millisec-

FP7-ICT-314739.

one of the systems integrators participating

ond clock speed on the servo level – allow

components

www.hephestosproject.eu

use of low-cost sensor systems in combina-

►►Key R&D foci

»Control Technologies« module develops

in the project is currently building a flexible

for integration of the user’s own control

tion with intensive model-based processes

Research and development work in the

advanced control procedures in association

robot machining cell as an integrated dem-

modules. This means that novel process

or software solutions. In this way an opti-

HEPHESTOS project covers four key mod-

with open control concepts and is particu-

onstration system. Application focus is on

strategies and control techniques can be

mal combination of offline planning and

ules. In the first module »Planning and Pro-

larly concerned with researching techniques

the machining of large-scale components

very flexibly realized on an external control

Your contact

online control processes can be achieved

gramming Tools« the focus is on extend-

for controlling the force and compliance of

with complex surface structures such as gas

PC and tested on real industrial robots. In

Gerhard Schreck

that factors in practical user experience

ing the CAD/CAM-process chain for offline

machining processes. Access to the specific

turbine components and ships propellers.

this respect the Fraunhofer IPK experts are

Phone: +49 30 39006-152

and user process know-how. The basic ele-

program generation with models of robot

control functions and models of a robot is

One of the main aims of research work at

using their own tried and tested module for

gerhard.schreck@ipk.fraunhofer.de

ment here is an open integration environ-

and process behavior and interactive com-

enabled via open interfaces. The focus of the

Fraunhofer IPK is to develop and optimize

force and compliance control.

ment for planning, programming and con-

ponents. This will enable consideration of

»Sensor Systems« module is on the develop-

control techniques for robot-assisted

Dr. Dragoljub Surdilovic

trol. The relevant parameters for mechanical

the characteristics of the robot system early

ment of application-oriented and thus low-

machining. To this end scientists are inves-

Phone: +49 30 39006-172

machining such as removal rates and surface

on in the planning phase, i.e. it will allow

cost force/torque sensor systems for process

tigating techniques for the control of force/

dragoljub.surdilovic@ipk.fraunhofer.de

13

14

Research and Development

FUTUR 1 – 3/2014

Robotics

Ensuring Process Stability Milling with Industrial Robots Over the past few decades industrial robots have proven their value in a broad spectrum of sectors in industrial production. Alongside traditional areas of application such as materials handling and welding, they have also been established in the field of mechanical machining, for such tasks as grinding, polishing and

Axis 1

Axis 1

deburring, but also, and increasingly, for milling. With their low investment costs, large working space and high flexibility, using industrial robots to perform

The first two normal modes of oscillation of the industrial robot

machining tasks traditionally reserved for tool machines is a move that pays dividends. In response to the rising demand for robot-based manufacturing systems, some manufacturers are offering robot cells which feature all the components needed to use an industrial robot as a machining tool. Fraunhofer IPK uses such

Stable Process (aP = 1,0 mm)

a robot milling system for research purposes.

►►Research challenges

the service life of the machining system. The

the system is never fully tapped. This is the

cantilever. In contrast, the dominant natural

Despite all the progress made since the

major factor at play here are the self-excited

area investigated in the following studies

frequencies of the electrospindle at high fre-

first research projects in the 1990s, two

vibrations resulting from dynamic interac-

conducted at Fraunhofer IPK in association

quencies lie between 1,000 and 2,000 Hz.

key problems still remain with respect to

tion between the machining process and

with the Department of System Reliability

machining with industrial robots. On the

the compliant machining structure. The two

and Machine Acoustics at the Technical Uni-

one hand, the low level of rigidity they dis-

main stimulation mechanisms are mode cou-

versity of Darmstadt.

play in comparison to machine tools leads

pling and the regeneration effect. These two

to the tool being statically pushed from

mechanisms have thus far received scant

its programmed path and thus to reduced

attention in the field of robot-assisted mill-

►►Analyzing vibrations in the milling process To characterize the behavior of the overall

►►Vibration behavior of the robot milling system

1 mm

Robot Infeed

Chatter Marks

Instable Process (aP = 2,0 mm)

system during the milling process a series of milling tests with the aluminum alloy

accuracy in the finished component. And on

ing. A lack of understanding of how the

A holistic system analysis must consider not

7075 were carried out. During the machin-

the other, vibrations occur in the tools and

system functions has led to a preference for

just the industrial robot but the electrospin-

ing of a workpiece flank an instable pro-

machines which not only have a detrimen-

conservative cutting parameters in an effort

dles and positioners as well. As components

cess caused by the regeneration effect was

tal effect on surface quality, but can also

to avoid such »chatter vibrations« which

lying in the flux of force, these play a deci-

noted. While machining traces due to the

speed up the wear of the tool and shorten

means that the performance potential of

sive role in the relative movement between

tooth feed from the interrupted cut were

be made that allows for milling at a greater

features which are not optimized for milling

tool and workpiece at the machining point.

noted during a stable process, clear chat-

cutting depth.

applications. It is now up to robot manufacsystems for the growing market for machin-

General view of the robot milling system at Fraunhofer IPK

Electronic Spindle

Robot

Positioner

A workpiece flank for a stable (above) and unstable process (below)

ful adjustment of the rotational speed to

tion of both robots and positioners display

While the first natural frequencies generally

ter marks were apparent at a cutting depth

occur between 50 and 75 Hz in conventional

of two millimeters. The tool vibrated out

►► Need for future research

turers to adapt and enhance their standard

tool machines, in the KUKA KR 60 articu-

of phase with the tooth contact in a nat-

Along with mode coupling induced process

ing with industrial robots.

lated arm robot under investigation they lay

ural frequency that can be attributed not

instability as documented in the literature,

Original German text: David Schylla

between 7.3 and 9.6 Hz in a key machining

to the industrial robot but to the spindle

regenerative chatter vibrations also appear

position. The associated forms of vibration

system. Yet this resulted in low frequency

in robotic milling. The machining tests car-

are characterized by the rotation or tilting

waviness on the workpiece flank since the

ried out showed that the dynamic behavior

of the robot arm round the base frame due

vibration with the highest amplitude exactly

of the electrospindle had a major influence

to compliance of the gearbox and bearings.

corresponding to the difference frequency

on process stability during machining of the

These eigenmodes can be combined during

between the tool vibration and tooth mesh-

aluminum. Use of stability diagrams, as

Your contact

the machining process and lead to a high

ing frequency was dominant in the machin-

known with tool machines, offers the pos-

Sascha Reinkober

vibration amplitude in the industrial robot.

ing defect. Speed-dependent stability

sibility of selecting stable process parame-

Phone: +49 30 39006-326 sascha.reinkober@ipk.fraunhofer.de

The positioner, on the other hand, displays

behavior with the regeneration effect was

ters and thus of making better use of the

low compliance and thus has its first natural

mapped in stability diagrams. The insight

capacity of the robot milling system. Accord-

frequencies at 30.5 and 37.5 Hz. Its static

gained in the vibration analysis about the

ingly, future research projects should pay

Marcel Manthei

and dynamic weak point is the constructive

system’s natural frequency as a root cause

more attention to the dynamic behavior of

Phone: +49 30 39006-245

design of the base frame as a hollow-walled

of process instability now enables purpose-

the tool spindle. Furthermore, the construc-

marcel.manthei@ipk.fraunhofer.de

15

16

Research and Development

FUTUR 1 – 3/2014

Cutting Technology

More Functions for More Efficiency A New Turning Tool Design Over the past decade the laser as a means of measurement and production has helped push back the frontiers of what’s technically feasible. The new design possibilities created by generative manufacturing enable engineers and designers to enhance the capabilities of proven tool systems. The Collaborative Research Center CRC 1026 Sustainable Manufacturing draws on these possibilities to redefine the status of current research in terms of its economic, ecological and social aspects.

Scientists at the Institute for Machine Tools and Factory Management IWF at the Technical University of Berlin have evolved the evo.T5, a fifth generation turning tool. Not just its striking appearance sets this tool apart from other systems, its superior vibration and temperature behavior, integrated open or closed cooling system and tool condition monitoring also put it in a class of its own.

►►Low-cost tool cooling

ducted away and thus is separated from

for dry processing

the rise in temperature during actual cut-

a very marked positive effect on the ecologi-

ting time.

cal footprint of the tool. With no change in

Dry processing is a production technique characterized by low power consumption and lean manufacturing as there is no need for the production, monitoring and disposal

fabrication of indexable inserts as these have

the cutting stability, and for increased cool-

►►The evo.T5 –

ing performance, the thickness of the index-

a multifunction turning tool

able insert was reduced from 2.38 to 1.06

of cooling lubricants. This both saves on

Turning tools with closed internal cooling

millimeters bringing with it a corresponding

downstream cleaning and eliminates work-

systems must meet a different set of require-

52 percent reduction in the weight of the

ing time lost due to sickness caused by con-

ments to conventional tools. In particular

indexable insert. This means that fabrication,

tact with cooling lubricants. However, there

they must ensure mechanical stability under

operation and recycling of the tool are now

is no cooling of the cutting edge and the

the temperature range of the deployed cool-

much more sparing and efficient in their use

positive effects of lubrication on an inter-

ing medium from minus 210 to plus 40

of materials and energy.

rupted cutting process are also lost. In a

degrees Celsius. Nor should the position of

worst case scenario, a switchover to dry

the cutter shift when the cooling system is

►►Parallel process tool monitoring

processing will involve downward revision

operational. Otherwise this results in marked

The holder of the novel turning system also

The topology-optimized turning tool evo.T5 with its closed internal cooling system.

of the wet processing cutting parameters

variations in the geometry of the finished

features integrated temperature and tool

which means that the savings on cooling

components. To prevent this the cooling

monitoring channels alongside its cooling

lubricants and the benefits of lean manu-

medium channels integrated in the evo.T

medium in- and outfeeds. The measurement

facturing processes are offset by loss of pro-

body are decoupled from its support struc-

values they give enable determination of the

Use of an internal cooling system reduces

ductivity. Or alternatively cooling can be

ture. As manufacturing of flow-optimized

heat flux conducted over the tool. In com-

heat induced diffusion wear by one and a

peratures have an exponential influence on

effected with compressed air, solid carbon

cooling channels is difficult, selective laser

bination with performance measurement of

half times in the dry processing of titanium

the rate of diffusion and thus the rate

dioxide or liquid nitrogen. These alternative

melting is used for fabrication of the tool

the main spindle and feed axes, this enables

alloys. The high temperature resistant tita-

of wear. What’s more, tests have shown

cooling agents volatilize in the machining

holder. This production technology enables

real-time computation of the energy flow

nium alloy TiAl6V4 with its high machining

that in comparison to wet processing

zone, yet their application comes with such

coordination of static and dynamic tool

and efficiency of the machining process.

temperature and responsiveness favors

overall energy consumption can be re-

high costs that only in exceptional cases are

rigidity with minimal use of materials. Opti-

Such information is vital as it enables paral-

decomposition of the cutting metals which

duced by 21 percent with the same metal

they economically viable.

mized topology enables the material of the

lel process determination – with account

sets in at around 650 degrees Celsius in

removal rate.

tool holder to be placed exactly in the posi-

taken of tool wear – of maximum pro-

tungsten carbide tools with cobalt binder.

tion where it will absorb and conduct force.

ductivity through minimal use of energy

With its closed internal cooling system, the

and resources.

evo.T5 turning tool reduces the temperature

Your contact

Another solution for low-cost tool cooling

5

is closed internal cooling systems which use

►►Less energy consumption through closed internal cooling

Reduction of the temperature significantly reduces heat-induced machine wear through diffusion effects since cutting tem-

a heat sink to disperse the tool’s machining

►►Resource-saving indexable inserts

level by up to 40 degrees Celsius depending

Paul Fürstmann

heat in a cooling medium. The heat that

Savings in basic materials investigated by

on process parameters and cooling perfor-

Phone: +49 30 314-21791

accumulates in the tool is targeted and con-

the CRC 1026 will also be applied to the

mance and maintains it steadily on this level.

fuerstmann@iwf.tu-berlin.de

17

18

Research and Development Research and Development at the Production Technology Center Berlin

Cutting Technology

FUTUR – SPECIAL Vision Innovation Realization

Precision Laser Measurement of Wear during Machining The precise measurement of the width of wear marks for assessment of the

Education

degree of displacement on the tool’s cutting edge is a costly and time-consuming procedure both in laboratory and factory conditions. Determination of the degree of wear on a single cutter can take several hours and the whole procedure must be repeated several times to be statistically validated. To optimize the machining process and with regard to the future project Industrie 4.0 and the associated trend to tool monitoring and diagnostics, the Institute for Machine Tools and Factory Management IWF at the TU Berlin has developed a measuring system that can measure flank wear during the actual turning process.

Continual retraction of the cutting edge

scenario quality control only notes inadmis-

Measurement errors in the micro millimeter

caused by abrasive and adhesive wear is one

sible deviations in workpiece geometry and

range have a powerful impact on real mea-

of the reasons for deviations in the end

roughness after processing of the work-

surement values and necessitate further

geometry and fabrication quality of compo-

pieces which means that they have to be

measurements. With their high resolution

nents. This is because tool machining time

reworked or even scrapped.

and repeat accuracy, the shelf laser triangu-

shape and position of the cutting edge. A

►►It all depends on µ!

securely fixed to the tool holder can mea-

and the wear it brings with it change the

lation measurement systems whose laser is

further detrimental effect is the uneven

To assess the degree of wear on the cutting

sure the displacement of the cutting edge

development rate of wear effects which in

edge, in practical terms the width of wear

during the turning process. The laser beam

the machining process leads to a reduction

marks has established itself as a benchmark

hits the ever new cutting surface created by mapping of the cutting edge and measures

The high precision laser position sensor for measuring displacement of the cutting edge during the machining process.

point by point the continually growing displacement of the cutting edge. If alternatively a 2D laser is used, the development of wear can be measured across the whole cutting width.

►►Quick, easy and precise The laser measurement system developed at IWF is machine- and tool-independent and can be adapted for left and right cutting tools. In machining trials with the hypereutectic aluminum casting alloy AlSi17 development of wear could be monitored parallel to the process from the first cutting action in the effective cutting edge radius and an

as such width can easily be determined by

to the end of service life. It is now possible

increase in workpiece roughness while the

a microscope after removal of adhesive

to interrupt the cutting process if a pre-

workpiece materials. On the other hand,

defined wear criterion is exceeded. Further-

measurement of the cutting edge displace-

more, the remaining period of tool service

feed rate remains constant. In a worst case

ment poses major challenges to both the

life can be computed parallel to the process

accuracy of the measurement system and

from the temporal development of cutting

Paul Fürstmann

the skills of the operator as the cutting edge

edge displacement. The machine control

Phone: +49 30 314-22424

displacement is smaller than the width of

system can then decide on a suitable point

fuerstmann@iwf.tu-berlin.de

wear marks by a factor of approximately ten.

in time for replacement of the tool.

Your contact

International Master’s Program Rita Süssmuth Interview

Manufacturing and Renewable Technologies

One Hundred Years of History

INSTITUTE PRODUCTION SYSTEMS AND DESIGN TECHNOLOGY

INSTITUTE FOR MACHINE TOOLS A N D FA C T O RY M A N A G E M E N T T E C H N I S C H E U N I V E R S I TÄT B E R L I N

20

Education

FUTUR 1 – 3/2014

Germany

GPE – International Master’s Program in Manufacturing and Renewable Technologies In an interview in 2002, Professor Günther Seliger described the TU Berlin’s international master’s program Global Production Engineering GPE as a »deliberate attempt to break with the one-sided economic approaches of modern international MBA programs through incorporation of proven German engineering content«. Subscribing to this approach, the GPE – introduced by the Technical University of Berlin in 1998 – has now established itself as a successful international master’s program in Germany in the field of production technologies and factory management.

This success, mirrored in the more than

of global companies. Planning and design

1.200 applications from over 40 countries

of sustainable factories and processes is

of capability in IT tools for the planning and

received each year, is due in large part to

one major educational focus together with

design of products and processes. The cur-

program is also the instilling of a proper level

Start

GPE students at the solar laboratory

October 1, 2015 Application Deadline

►►GPE – a decidedly international

the inclusion of top decision-makers from

production planning and control, process-

riculum includes courses on how to work

►►GPE major New Energies

global companies in the academic staff, and

oriented factory layout and virtual product

with enterprise resource planning software

In this major students are offered the oppor-

the teaching of material with international

design. The major further aims to provide

such as SAP, computer-aided design pro-

tunity to become experts in specific renew-

Over the past decade, the special nature of

Two years (three semester courses plus one

perspectives in fields such as sustainable

future graduates with a broader vision on

grams such as Solid Edge and ProEngineer,

able energy technologies, e.g. photovolta-

GPE as an English language international

semester internship and master thesis)

manufacturing, industrial management and

competition between global companies,

planning tools for modeling production

ics, solar thermal and wind energy, and to

master’s program in the heart of Europe has

Fee

renewable energy technologies.

modern automation and innovation meth-

facilities such as Technomatix, and logistics

become competent in grasping the big pic-

attracted a student body from over 40 coun-

15,500 euros plus approx. 300 per semester

ods, and new production techniques and

chains such as AIMMS.

attitude

March 31, 2015 Duration

ture and gaining insights into the renewable

tries on five continents. Each year a student

for administration costs and public transportati-

Another key to success worth mentioning

technologies by means of what are called

energy mix. The course covers aspects of the

roll-call of some 60 to 90 outstanding stu-

on system ticket

is the outstanding quality of graduate stu-

»learnstruments«. Especially relevant for the

value creation chains of relevant new energy

dents is selected from over 1.200 applicants

A Master Program for

industries from the design of elements, com-

to spend the next two years improving their

–– outstanding international graduate stu-

ponents and systems through to the evalua-

technical, managerial and communication

dents seeking to improve their personal

tion of global markets and implementation

skills with peers from across the world. With

competence portfolio in the fields of pro-

dents applying each year for the program.

Each of the 60 to 90 students accepted each year already have at least one year’s pro-

Explaining robot technologies in GPE’s test field

fessional experience in global companies,

potentials in specific world regions. This is

over 450 alumni, GPE has also created a vast

duction, management, engineering, and

which thus adds a multi-directional knowl-

achieved through an appropriate knowl-

global network of decision-makers and

intercultural communication.

edge transfer effect to the content taught

edge transfer of the physical, electrical and

emissaries of sustainable manufacturing

Admission Requirements

in the classrooms. The infrastructure offered

mechanical properties of the main tech-

concepts in global companies around the

–– Bachelor of engineering or equivalent with

by Fraunhofer IPK, one of the best-equipped

nological components, as well as through

world. The alumni community also serves

applied research institutes in Germany, fur-

analysis of current and future energy mar-

as a platform for international information

ther enables students to become acquainted

ket trends on a global scale. Furthermore,

exchange, mutual support and as an incuba-

TOEFL IBT 70 or TOEFL CBT 190 or TOEFL

with the latest in manufacturing technolo-

the modular structure enables courses to be

tor for collaboration. This is why GPE gradu-

PBT 520 or CAE Pass or CPE Pass

gies and modern technical management.

arranged flexibly in line with students’ needs.

ates are now to be found working in such

Technical knowledge is complemented with

engineering challenges such as construction

►►GPE major Manufacturing

courses on project management, finance,

of the Shanghai subway, production of Ger-

GPE currently offers two majors: Manu-

intercultural communication, as well as on

man automobiles in Latin America or in

facturing Technology and New Energies.

the policy and legal framework. Current

research projects for the set-up of sustainable

The Manufacturing major was introduced

developing topics in the sector such as net-

manufacturing factories in the Amazon.

in 1998. The program is designed to train

work integration and energy storage are

undergraduate students as manufactur-

also addressed.

excellent grades –– English knowledge at least: IELTS 6.5 or

–– At least one year of professional experience More Information www.gpe.tu-berlin.de

Your contact

ing engineers with a deep understanding

Jens Palacios

of state of the art production technologies

Phone: +49 30 314-73808

and the technical management methods

palacios@mf.tu-berlin.de

21

22

Education

FUTUR 1 – 3/2014

Vietnam

GPEM – Master of Science in Global Production Engineering and Management

engineering, management and intercultural

alumni to access technology-oriented com-

full tuition for the two-year GPEM Master

communication. After successfully complet-

panies and organizations and enable them to

program, a living scholarship of 100 USD per

ing the course, students receive a German

be entrepreneurs. GPE graduates are often

month for the whole two years of study, and

university degree from the TU Berlin.

employed in managerial positions, and act as

a working contract with adidas and its global

interface among multi-national companies.

suppliers in HCMC, Long An, Binh Duong,

The GPEM Master’s program is linked to the

Dong Nai after graduation. In addition, VGU

European Credit Transfer System ECTS. One

►►Project work

provides merit scholarships on an annual

Manufacturing is one of the fastest growing sectors of the economy in Vietnam,

credit point CP equals on average between

As part of an international project, students

basis for the best 10 to 30 percent students,

in large part due to German direct investment. To cope with such rapid economic

25-30 student working hours. The Master’s

of the GPEM class 2013 have for the last six

as well as social scholarships for students

growth, companies need well educated engineers who can meet high quality

program comprises a workload of a total

months been working on the development

with especially difficult financial situation.

standards and intercultural communication requirements. The Master's program

of 120 credit points (CP). Teaching modules

of gasifier prototypes. Gasifiers are furnaces

»Global Production Engineering and Management GPEM«, offered at the Viet-

of together 90 CP must be taken. Further-

for the production of charcoal, a vital com-

namese-German University VGU by the Technische Universität TU Berlin since

more, students must complete a nine week

ponent in sustainable Terra Preta Sanitation

2013, prepares students for careers in international networks in the area of

internship with 12 CP at companies in Viet-

systems. Four project groups of Vietnam-

technology management. Rather than only focusing on business administration,

nam with some kind of German ownership.

ese students developed concepts for the

GPEM enables engineers to create systematic technological innovation combined

The GPEM study is completed by presenting

production of gasifiers that took account

with efficient and effective industrial business management.

independent scientific work in the form of a

of factors such as production conditions in

Master's thesis (18 CP) with approximately

Vietnam, raw materials and market condi-

three months processing time.

tions. The best group tested their prototype

Start

in August 2014, producing charcoal from

October 2015

►►Study subjects

rice hulls at IWF in Berlin. In September 2014,

Application Deadline

In terms of its learning objectives, GPEM is

the same group took their gasifier proto-

July 2015

built on a combination of entrepreneurial-

type to Malaysia for the »Global Conference

Duration

and management-oriented content with a

on Sustainable Manufacturing«. They pre-

full-time two-year (4-Semester)

focus on design and production technol-

sented it together with a Terra Preta toilet

Fee

ogy. The theory of flexible, adaptable, and

system designed by TU students.

25.000.000 VND (950 euros) per semester

virtual factories is a major educational focus.

The opening ceremony of the GPEM study program with TU Berlin and VGU officials and students in October 2013

A Master Program for

Production planning and control, process-

►►adidas and VGU scholarships

oriented factory layout, CaX programs and

The GPEM Master's program with its practi-

cal, industrial or electrical engineering,

virtual design are all part of the mix. Design-

cal approach and the quality of a leading

informatics and related fields who want

ing global supply chains and factory man-

German university has attracted special

to acquire advanced knowledge and

agement are key in the area of economics.

interest from adidas and its global suppliers.

skills in their field and seize better job

IT tools for planning and designing products

In search for engineers with production

and processes are introduced, and students

management skills acquired through

learn how to program and use them. The

German-standard training, they offer a gen-

gained knowledge and qualification allow

erous scholarship package which includes

–– Bachelor degree holders in mechani-

opportunities, –– students interested in intercultural learning, team work and entrepreneurial thinking.

Admission Requirements –– a Bachelor degree in engineering,

The Vietnamese-German University is a pub-

Institute for Machine Tools and Factory Man-

GPEM students with scholarships. For the

lic university that opened in 2008 in Ho Chi

agement IWF at the Technical University of

first two enrolments since 2013, there were

Minh City. It is based on a close partnership

Berlin since 1998. Bachelor degree holders

approximately 600 applicants, of which 55

–– advanced English skills,

of the most talented were selected.

–– VGU entrance test on technical subjects

between the Socialist Republic of Vietnam,

from all over the world join GPE to learn

the state of Hessen of the Federal Republic

about state of the art production technol-

of Germany and nine German universities

ogy and technological management. Much

►►Program description

and colleges. Since 2008, a total of twelve

like its role model, GPEM addresses today's

GPEM is a full-time study program over

degree courses, inlcuding seven Master’s

industrial problems. For a build-up phase

four semesters, carried out entirely in Eng-

and five Bachelor’s, with more than 750 stu-

of three years, the program is coordinated

lish and promoting technical competencies

dents have been implemented.

VGU and TU Berlin students with their prototype at the Global Conference on Sustainable Manufacturing in Malaysia, September 2014

technology or other disciplines plus working experience in production,

and English language proficiency.

More Information www.vgu.edu.vn

by the German Academic Exchange Service

in engineering disciplines, development of

DAAD and supported by the Federal Min-

manufacturing processes and tools, model-

Your contact

The new GPEM program at VGU is modelled

istry of Education and Research BMBF. Fur-

ing and simulation, quality control and eco-

Peter Stammnitz

after the Master's degree program »Global

thermore, industry partners such as Adidas

nomic evaluation. Students may design indi-

Phone: +49 30 314-26866

Production Engineering GPE« run by the

AG and their suppliers support over half the

vidual qualification profiles in production,

stammnitz@mf.tu-berlin.de

23

24

Education

FUTUR 1 – 3/2014

Turkey Smart Factory

MSE – Bachelor Program on Mechatronic Systems Engineering

Metrology and Diagnostics

Mechatronic Systems

In April 2014, the German Federal President Joachim Gauck and the former Turkish president Abdullah Gül inaugurated the Turkish-German University TDU in Istanbul. Launching this partnership, the Bachelor of Science program in MechaMechanics and Material Science Design of Machine Elements

tronic Systems Engineering MSE was initiated in September 2014. The consulting team for the Engineering Faculty at the TDU is composed of representatives from

Mechanical Engineering

the Institute for Machine Tools and Factory Management IWF at the TU Berlin and the Fraunhofer Institute for Production Systems and Design Technology IPK.

Structure of MSE study program

The team is responsible for the scientific coordination and implementation of innovation study programs, as well as for the establishment of an engineering

Prof. Jörg Krüger of Fraunhofer IPK and IWF gives a lecture on the introduction of industrial information technologies at TDU in Istanbul.

technology center for applied science at TDU.

Start September 2015 Application Deadline

►►Why is this international partnership important for Germany?

ground. In terms of a European comparison,

to the ever-increasing demand, German

In the light of such changing requirements

Another special feature is the trilingual edu-

June 2015

Turkey with a population of 76 million peo-

com-panies are setting up new production

for engineers, the newly designed study pro-

cation offered to students. All teaching at

Duration

The five sectors with the highest percentage

ple represents the second largest demo-

sites in Turkey.

gram trains students by setting out three

the Bachelor’s level is expected to be done

full-time four-year (8-Semester)

of engineers employ ten percent of the

graphic and – with an average age of 31

areas of focus: knowledge in the fields of

in German and in English at the Master’s

Fee

entire labor force in Germany and account

years – also the youngest community.

Although Turkish industry is now well posi-

mechanical and electrical engineering, pro-

level. Classes will be taught in parallel in

Tuition fee for public universities in Turkey

tioned in terms of production of state of the

duction and information technology, as well

German and Turkish in the first two semes-

A Bachelor Program for

age of engineers in Germany currently is

Looking at its economic significance, Turkey

art products, the next industrial transforma-

as economics, skills in sustainable develop-

ters, while starting with the fourth semester

Students interested in

over 50. Over the next ten years, more than

as a non-EU country is Germany’s sixth trade

tion will be a move to sustainable develop-

ment of technological solutions, e. g. cyber-

classes will also be taught in English.

–– core competencies in mechanical and elec-

one in two qualified German engineers

partner in terms of trade volume and comes

ment and production of innovative products

physical production systems in smart facto-

for 45 percent of total revenue. The average

trical engineering, information and produc-

►►What are the selection criteria

working for German companies abroad, and

in at fourth place as a target export market.

for European and international markets. As

ries , and soft skills through project-oriented

almost one in four engineers working in

The number of German-Turkish companies

such a move calls for in-house research

courses in intercultural and interdisciplinary

Germany will retire. German higher educa-

now totals 5,750. With more than 370,000

and development, the TDU could well func-

teamwork. Of special importance is the

Students enrolled in the first MSE class either

and industrial-grade solutions of mecha-

tion institutions alone cannot meet the con-

employees, these companies generate

tion as a bridge between the two nations,

strong involvement of industry partners in

have taken the university entrance exam

tronic applications,

sequent annual demand of over 80.000

annual revenue in the order of 35 billion

combining application-oriented research

establishing research projects, project-ori-

ÖSS instigated centrally by the Turkish

graduates on the employment market.

euros. Products in the automotive, home

in Germany with production-strong in-

ented courses and internship opportunities

Higher Education Council YÖK, or have

appliances, medical devices and energy sec-

dustry in Turkey.

for students in Germany and Turkey.

gained the German equivalent of the high-

To date, more than ten percent of engineers

tors, as well as equipment and plant con-

working in Germany have a migrant back-

struction are highly sought-after. To respond

school diploma »Abitur«. Two million can-

►►What will engineers study in the new MSE courses?

The new TDU campus in Istanbul: construction is planned to start in 2015 and to be completed in 2016.

(Visualization: Hilmi Güner)

for students?

tion technology, and economics, –– skills for the development of sustainable

–– opportunities to focus on smart factories and cyber-physical production systems, –– soft skills, cultural sensitivity training and project work in interdisciplinary groups.

►►What’s special about

didates sit the ÖSS examination each year.

Admission Requirements

the MSE program?

MSE students are among the top 0.2 per-

–– Successful participation in the Higher

The challenge of the fourth industrial revolu-

The project benefits from strong industry

cent of their graduating class. In the winter

Education Examination – Undergraduate

tion stems from the proliferation of industrial

cooperation and interest and from volun-

semester 2014/2015, the TDU engineering

Placement Examination ÖSYM, or German,

information and communication technology

tary participation by a range of experts. The

faculty totaled 90 students, 17 of whom

together with increased levels of cross-pol-

course concepts have been developed over

have started the first semester of the MSE

Austrian or Swiss »Abitur«, –– TDU entrance test on German and English

lination between different disciplines such

the course of the past three years in consul-

Bachelor’s course. 30 percent of the stu-

as engineering, information technology and

tations between the two nations involving

dents are women. Five students have

More Information

economics. The engineers of the future will

the participation of more than 30 universi-

a German high school leaving certificate.

www.tau.edu.tr

need to develop, test and implement broad

ties with some 60 leading professors from

The other 73 students are attending a Ger-

language proficiency.

systemic solutions for the complex chal-

the fields of mechanical and electrical engi-

man language preparatory course this

lenges awaiting society, the economy and

neering, computer science, production tech-

school year.

science. However, they must equally develop

nology, automation and business administra-

Soner Emec

an awareness of the sustainabi­lity factor in

tion as well as industry partners.

Phone: +49 30 314-22852

the critical analysis of their solutions.

Your contact

emec@mf.tu-berlin.de

25

26

Education

FUTUR 1 – 3/2014

Interview

One Hundred Years of History A German University in Turkey with a Focus on Applied Science ress in partnership. There are many wom-

the Fraunhofer model has already been pro-

In 2008 the German and the Turkish governments signed a cooperation agree-

en's organizations in Turkey. And one of

posed in the memorandum between the

ment to establish a Turkish-German University TDU in Istanbul. The Institute

the strongest in terms of membership and

two governments.

for Machine Tools and Factory Management IWF of the Technical University of

female power is the women's association

Berlin will assist TDU over the next few years in the roll-out of a new education,

of small and medium-sized entrepreneurs.

research and development strategy for engineering at TDU. FUTUR talked to the

FUTUR: How can TDU as a young institution with a long history contribute to relations

president of the TDU consortium, Professor Dr. Rita Süßmuth, former president

There are certainly shortcomings in Tur-

of the German Bundestag, about the history of German-Turkish cooperation in

key but it should be noted that Turkey is

science and the founding of TDU.

considered to be very open in terms of its

between Europe and Turkey?

Süssmuth: I cannot imagine Europe in the

About Rita Süssmuth

refugee policy. Political refugees and Jews

long term without Turkey. The TDU is an

Professor Dr. Rita Süssmuth, born in 1937 in

sought refuge in this country during the

excellent way of shedding light on current

Wuppertal, is a German politician (CDU). She

FUTUR: The idea of a German university in

was the effort made between 1993 and

passed by parliament. The required law was

time of National Socialism. Among these

world issues, and it also serves as a living

was Federal Minister for Youth, Family and

Turkey has been around for over 100 years.

1997 with Chancellor Helmut Kohl and for-

signed in 2010. Istanbul was chosen as the

was the father of Edzard Reuter, Professor

example of the productive and sustainable

Health from 1985 to 1988 (from 1986: Youth,

How did you become involved with the Turk-

mer Turkish President Suleyman Demirel.

site as it represents the bridge between Ori-

Ernst Reuter, who among other things was

coexistence of cultures that allows each side

Family, Women and Health) and from 1988 to

ish-German University?

Although template designs for relevant

ent and Occident.

also the first mayor of Berlin after the Sec-

to gain a broader understanding of the

1998, the second female president of the

ond World War. Present-day Turkey owes

other. In Turkey there are some voices which

German Bundestag. Her tenure was the second

some of the foundation blocks of its current

say that even if we never join the EU, the

longest in the history of the Bundestag – almost

courses were drawn up, the university itself Professor Dr. Rita Süssmuth: Initially I

failed to materialize. Nobody knows the rea-

heard about it through my work in the field

son for that failure.

of immigration and integration. Already in

FUTUR: Like Professor Georg Schlesinger, founder of the first Chair of Machine Tools

education and research policy to these refu-

process itself has already helped to guide

ten years. Her achievements have been

and Factory Management, many German

gees. From them and their legacy we should

our country in the right direction in terms

honoured with six honorary doctorates, a lot of

1994, in a small book of interviews, I had

FUTUR: How did the activities for a new

scientists sought refuge in Switzerland or

learn to pursue a balanced policy with Tur-

of politics, economics and research. With its

national and international awards such as the

asked for a law on immigration. Many

venture start this time round and who were

Turkey during World War II. From a pres-

key, with both countries as equal partners.

geopolitical location, Turkey enjoys a special

Leibniz Medal of the Academy of Sciences and

claim­ed at that time that Germany was a

the main actors?

ent day perspective, how do you assess

place in the Arab world. When some say

Literature in Hannover and the Order of Merit

the impact these refugees had on Turkish

FUTUR: What kind of research profile does

that without Russia peace is not possible in

of the Federal Republic of Germany. She was,

the Turkish-German University have?

typical »rotation country« and condemned my work as doomed to failure. However, I

Süssmuth: It all began shortly before the

higher education and cooperation between

did not let myself be discouraged and went

departure of the German ambassador Eck-

the two nations?

ahead. At that time I had some consultants

art Cuntz from Turkey in 2006. He invited

in this field on my side from the Volkswa-

me to dinner and I told him of the idea of

gen Foundation. After my time in the Bund-

a Turkish-German University. His response

between the two countries even before the

ing a research university of excellence with

In rejecting criticism of the instrumentaliza-

University of Applied Sciences and current chair

estag, I was asked by Edzard Reuter, CEO of

was »What else would I love to do more!«.

First World War. The intention now is to

programs at the Master’s and Ph.D. level.

tion of bodies such as the TDU and its

of the Board of Trustees of the TU Berlin. In

Süssmuth: There was fruitful cooperation

Europe, I would add that the same applies

and still is, director, president and CEO of

to Turkey and the Arab world. So it is

several foundations, associations, commissions

Süssmuth: From the very outset interest on

extremely important for Europe to maintain

on education and research, president of the

the German side was focused on establish-

a long-lasting, good relationship with Turkey.

European Movement Germany, of the SRH

Daimler-Benz from 1987 until 1995, to do

In May of the same year, there was a Turk-

build on this tradition and act as a counter-

Only this failed to take Turkish law on higher

research interests, I have to point to the fact

1969 she was appointed as Professor of

some consulting work for a private Berlin

ish-German Economic Congress which the

point to the »clash of civilizations« that is

education into account which stipulates that

that matters such as politics, research and

Education at the University of Bochum. In 1973,

university of applied sciences SRH, which

former Turkish prime minister Recep Tayyip

so frequently propagated – particularly from

each state university must begin with educa-

industry are simply inseparable which is why

she accepted an appointment as full professor

had been founded by an entrepreneur of

Erdoğan also attended. The ambassador

America. Compared to other countries such

tion at the Bachelor's level. Accordingly, the

the TDU should act as mediator of values in

at the University of Dortmund. Since 1971, she

Turkish origin.

organized a short meeting between us, and

as France, England and the United States,

memorandum establishing the TDU in 2008

both directions.

Erdogan agreed to the project. The only

which are all engaged in partner universi-

agreed on a four-stage study system con-

During my work at the SRH, I approached

thing left to do at that point was to inform

ties in Turkey, Germany seems reluctant to

sisting of college level for language learning

Edzard Reuter with the idea of a Turkish-

the German Chancellor because without

press forward with the relationship, and this

(German, English, Turkish), undergraduate

German university for the first time. I knew

her consent the project could not be real-

certainly has to do with an outdated image

bachelor’s degree programs currently in Ger-

of failed attempts at such a venture. One of

ized. The plan envisaged long-term sustain-

of the country. One widespread perception

man, and advanced master's and doctoral

has worked on the Scientific Advisory Board of the Federal Ministry for the Family. Today she

Interview: Pinar Bilge, Soner Emec

works with the Technical University at Berlin and as honorary professor at Göttingen.

the first was by Dr. Hugo Grothe in 1906,

able cooperation with Turkey. The following

in Germany is undoubtedly connected with

programs which are expected to be taught

as described in his book »Contributions to

year the DAAD and the Ministry of Educa-

misconceptions about the Koran and Islam

in English. The University boasts a special

Your contact

Knowledge of the Orient«; another was in

tion and Research put together a financial

as a religion. We should not forget that parts

orientation to industry-related and applied

Büro Prof. Dr. Rita Süssmuth

1957, the year of the Turkish-German Cul-

plan. Turkish law posed a further hurdle, as

of the Koran mirror the Bible. The status

research and development. To this end, the

Bundeshaus, Platz der Republik 1, 11011 Berlin

tural Convention. Last but not least, there

universities there require a resolution to be

of women is that they look for more prog-

establishment of an affiliated institute after

Phone: +49 30 22777-998 rita.suessmuth.ma01@bundestag.de

27

28

Education

Education

FUTUR 1 – 3/2014

Jordan

MUREE – Bachelor Program on Renewable Energies

Germany

Teaching Sustainable Development Worldwide

»Modernizing Undergraduate Renewable Energy Education: EU Experience for

Our planet’s resources are limited. One billion people live in economically privi-

Jordan MUREE« is the name of an international partnership between the Institute

leged countries while the other seven billion strive for equal living standards

for Machine Tools and Factory Management IWF at the TU Berlin, Fraunhofer

using common technologies to meet their production needs. However, traditional

IPK and nine Jordanian and European universities and companies. Initiated in

technologies are excessive in their exploitation of resources – and the world’s

2012, the project is financed by the TEMPUS program of the European Commis-

population and consumption levels keep on growing. Sustainable manufacturing

sion and sets out to develop, integrate, accredit and evaluate a quality bachelor

strategies and technologies need to be developed and implemented, if we are to

degree programme in Renewable Energy in Jordan with an appropriate labora-

achieve overall sustainable development. Education on a variety of qualification

tory component jointly taught by universities in Jordan in accordance with the

levels plays a major role here. Accordingly, the Collaborative Research Center

Bologna Process.

CRC 1026 »Sustainable Manufacturing – Shaping Global Value Creation« has

Sustainable MANUFACTURING

placed a special focus on teaching sustainable manufacturing on a global scale. international teaching of renewable energies in programs such as its international

»I like this project because in Brazil, where

the three key areas of strategy development,

master’s degree course »Global Production

I study mechanical engineering, we do not

technological solutions and knowledge

engineers in making sustainable trade-off

Engineering – Solar«.

learn anything about sustainability,« says

transfer. »We need to increase our teach-

decisions. Products can, for instance, be

exchange student Derek who develops

ing productivity drastically, if we want to

made more sustainable by using renewable

teaching materials on sustainable manu-

be able to cope with the sustainability chal-

resources, factoring in ergonomic consider-

Apart from its input in terms of teaching

rent engineering tools that will assist design

material, IWF is also involved in the prep-

facturing in his project work at the Tech-

lenge,« says CRC coordinator Professor Gün-

ations and choosing modular design struc-

aration and training of local lecturers and

nische Universität Berlin. »It is the same in

ther Seliger explaining why such an impor-

tures. Another tool focuses on the planning

academics responsible for the internal imple-

my country,« agrees Nikko, his project part-

tant focus is put on knowledge transfer. »The

and design of value creation processes and

mentation of the teaching material and

ner from Greece. »Sustainability in engineer-

good thing about knowledge is that it is the

networks by introducing multi-perspective

methods in Jordanian universities. Thus far

ing is such an important topic but it is not

only resource that grows by being used!«

modeling in enterprise process modeling.

two international training seminars have

addressed at all.«

On the expert level the focus lies on

The tool automatically evaluates the

been held at IWF with the participation of

Jordanian MUREE trainers at TU Berlin’s facilities

This will ensure that universities in Jordan

the-art educational technologies. MUREE

over fifteen academics and trainers-to-be.

What these two students have experienced

Details of the integration of the MUREE

applies to all levels of formal education even

courses into the regular academic curricula

in industrialized countries as research has

of Jordanian universities, and for the inau-

shown for Canada, the UK and New Zea-

guration of the MUREE laboratories in early

land among other countries. The main chal-

2015, are now being finalized by the con-

lenge lies in the poor education of educators

sortium and will be formally introduced at

themselves with regard to the complex field

are well positioned to offer quality educa-

will thus contribute to a sustainable out-

the project’s annual meeting in Amman in

of sustainability, especially when considered

tion compatible with European standards.

come that will promote curriculum reform

January 2015.

in combination with technology. This results

The immediate aim of MUREE is to enhance

in engineering education and leave a long-

in a relatively low awareness about the

capacity and enable Jordanian partner uni-

term legacy for Jordanian universities.

technological impact of sustainable devel-

versities to develop sustainable renewable energy bachelor’s programs with state-of-

opment, not only in society in general but In accordance with the overall objective of

also among important stakeholders such as

the program and in close collaboration with

future decision-makers.

its Jordanian partner universities, experts

Cube Factory – a learnstrument for sustainable manufacturing

from IWF in Berlin have elaborated the

The CRC 1026 established at the Institute

Your contact

MUREE curricula for courses on wind energy

for Machine Tools and Factory Manage-

management tools that help decision-mak-

sustainability of value creation networks and

Jens Palacios Neffke

and solar thermal technologies. Course con-

ment at the TU Berlin in 2012 takes a holis-

ers control sustainability issues in a global-

allows for redesign. Furthermore, methods

Phone: +49 30 314-73808

tent and didactic approach are both based

tic approach to sustainable manufacturing.

ized world – tools like the design decision

for integrated management of tangible and

palacios@mf.tu-berlin.de

on prior experience gained by IWF in the

Its interdisciplinary research team works in

support assistant to be embedded in cur-

intangible resources are being developed

29

FUTUR 1 – 3/2014

by its numerous international teaching part-

an online platform, the »Sustainable Man-

solar energy. The master’s program is run in

nerships. CRC experts support the establish-

ufacturing Community«, where informa-

close collaboration with the Collaborative

ment and conduct of engineering courses

tion for transnational educational projects

Research Center. CRC researchers regularly

and laboratories that include sustainability

such as product designs and production

set project work in English for the interna-

issues as core topics at the Vietnamese-

technologies can be shared. Universities in

tional student teams pursuing their own

German University VGU in Ho-Chi-Minh

Gaza, the West Bank and Jordan have also

work which means that sustainable man-

City and the Turkish-German University

expressed interest in joining the FabLab net-

ufacturing forms part of the education of

TDU in Istanbul. One notable instance of

work. These universities were visited by CRC

future stakeholders from all over the world

such partnerships is the »Fabrication Labo-

members in 2014 during their lecture tour

who take the sustainability paradigm back

ratory for Sustainable Manufacturing« or

on sustainable manufacturing.

to their home countries after completing

»FabLab« for short that was built as a learnstrument prototype at the TU Berlin. The Teaching by disassembly: Ready-to-use education kit on resource consumption in manufacturing

their degree.

The Sustainable Manufacturing Community

FabLab is an application-oriented techni-

is currently implemented by CRC members.

Even so, if broad acceptance of measures

cal learning center with desktop machine

The FabLab data are only a small fragment of

for sustainable development and a true par-

and tested that will enable businesses to

Many workers are illiterate. And although

artifacts in manufacturing systems which

tools. Production technological projects

what it does since it was designed to be an

adigm change is to be achieved, there is one

implement effective sustainability manage-

many illiterate people speak more than one

automatically mediate abstract knowledge

sensitize students to issues of sustainable

open access platform where everyone can

target group for sustainability education

and functionality.

ment and secure competitive advantages.

language, this often does not include a stan-

This is of tremendous importance since

dard foreign language such as English. So

value creation. The FabLab at the TU Berlin

share their knowledge and solutions about

that cannot be ignored. This is children. Chil-

puts a special emphasis on 3D printing. In

sustainable manufacturing with everyone

dren are the ones who will have to face the

else for free.

the profit motive is a major incentive for

the issue is how to qualify workers despite

The sustainability challenge concerns every-

this field a learnstrument called the »Cube

changing business behavior. What’s more,

language and educational barriers? CRC

one and needs to be addressed on the global

Factory« was developed and built in the CRC

full consequences of what is being done or

researchers are also investigating how incen-

researchers are developing a »human-cen-

scale. Crossing language and qualification

1026. The Cube Factory is a self-sustaining

Another partnership is with Kasetsart Uni-

created its own project for developing and

tive mechanisms and institutions in general

tric workplace« that analyses worker motion

barriers is just one step in the direction of

3D printing system that can run on solar

versity Bangkok where a mobile and mod-

testing teaching materials for children of all

not done today. Accordingly, the CRC has

should be designed in order to ensure that

schemas with a 3D camera tracking sys-

a global sustainable community. A scien-

power and recycle plastics both from old

ular solar laboratory engineered by the TU

ages from toddlers to teenagers. New teach-

competition not only pursues profit but also

tem and gives workers nonverbal guidance

tific network is another. To give research

printing jobs and shredded plastic rubbish.

Berlin Institute for Machine Tools and Fac-

ing methods such as »teaching by dis- and

leads to sustainability in the environmental

with visual aids. This may be used to teach

a forum, CRC 1026 organizes the well-

Its user interface is kept so intuitive that no

tory Management is put to use in a two

reassembly« have been put into practice

and social domain.

workers more ergonomic working positions

established annual Global Conference on

previous knowledge is required to get an

week course on solar energy once a year.

with different groups of children. One out-

Sustainable Manufacturing GCSM, usually

object printed.

The experts giving the course are from the

come here is a ready-to-use education kit

master’s program on Global Production

for project days that examines resource con-

in emerging countries in order to stimulate regional networks of science and industry

Similar FabLabs are planned for the VGU

Engineering for international graduates at

sumption in manufacturing based on the

as a side effect of scientific exchange. If the

and TDU and will be connected through

the TU Berlin which has a special focus on

example of mobile phones. Furthermore,

sustainability logic can be implemented in the regional and local pursuit of higher living standards in such for the most part richly populated areas, this will be a major step

teaching materials for school teaching are Terra Preta solutions for the »Blue Responsibility Award«, Global Conference on Sustainable Manufacturing 2014, Malaysia

being developed as open educational resources and will be available nationally and internationally in German and English

forward in sustainable development on a

to explain sustainable global value creation

global scale. In 2014 a »Blue Responsibility

– a topic hardly addressed in schools and yet

Award« was launched at the GCSM in Johor

which plays such an essential role in meet-

Bahru, Malaysia. Endowed with prize money

ing the sustainability challenge of our time

of 10,000 euros, the award was offered to

and beyond.

engineering teams from all over the world for manufacturing solutions for a sustainable Terra Preta sanitation system. The first prize went to a team from Xavier University in the Philippines for their project »Post Terra Preta Sanitation System for Disaster

CRC experts on a Middle East teaching trip in 2014

Transitional Communities in the Philippines« Another target group that needs to be

for example, but can also help them learn

considered are the workers involved in the

completely new assembly processes or gain

– a concept that has already proven its practical value in disaster management.

Your contact

manufacturing process. In many parts of the

information on sustainability issues. In this

world the threshold in worker qualification

sense the system is what CRC researchers

The CRC’s commitment to sustainable devel-

Phone: +49 30 39006-246

is a typically low level of general education.

call a »learnstrument«. Learnstruments are

opment in emerging countries is reflected

ina.roeder@ipk-projekt.fraunhofer.de

Ina Roeder

31

32

Research and Development

FUTUR 1 – 3/2014

Robotics

The Operating Theater Route Planer Instrument Navigation for Minimally Invasive Surgery Nowadays minimally invasive techniques have become standard surgical practice.

its susceptibility to electrically conductive

robot-driven assistance systems such as the

new system will reduce the reluctance of

Physicians operate through tiny »keyhole incisions« only a few centimeters in size

and ferromagnetic materials. Furthermore,

da Vinci® surgical system have proven to

clinics to buy and use navigation systems.

which generally heal quickly. For patients this means that they have much less

to date both types of navigation systems

be prohibitively expensive and far from easy

Yet above all the major benefit of this new

post-operative pain and shorter hospital stays. Yet for the operating physician

cannot take sufficient account of the specific

to handle in the operating theatre. Against

technology will be for the patients, since

minimally invasive surgery is a much more technically complicated procedure that

needs of surgeons across a broad range of

this backdrop, Fraunhofer scientists are seek-

higher numbers of minimally invasive surgi-

requires a certain amount of experience. One of the main problems for surgeons

application cases. Yet if the full level of their

ing to replace cost-intensive and cumber-

cal interventions will mean shorter recovery

is finding their way to the operating field through the insides of the patient’s

capacity has not been exploited thus far, this

some measuring techniques with a software

periods and shorter hospital stays.

body. Optical instruments such as endoscopes and bronchoscopes and surgical

also has to do not only with space and cost

solution. Their approach is based on optical

navigation systems can facilitate the surgeon’s work. Yet to date all the navigation

aspects, but critically with the complicated

camera systems like video endoscopes and

systems available on the market have their downsides. Scientists at Fraunhofer

sequence of preparatory steps they require,

visualization cameras commonly used in

IPK are now researching novel techniques for instrument navigation which are

and the necessary technical understanding

operating theatres with whose help they

more accurate, intuitive and low-cost than comparable systems now available.

among medical personnel of how to use

gain navigation data. They also develop

the system.

algorithms with which to reconstruct the

Instrument navigation in clinical practice at the Charité –Universitätsmedizin Berlin

►►Ups and downs of instrument navigation

The graphic user interface GUI of the IPK instrument navigation system

The position of the patient or the field of

restricts medical personnel’s access to the

►►Camera-based navigation

surface in the field of view of the camera

operation and the position of the respective

patient as they need to take care not to

IPK experts are addressing existing technical

from the video data. This surface is continu-

Instrument navigation is a flexible assistance

surgical instruments also need to be calcu-

block the camera’s line of sight, and the

deficits and developing novel camera-based

ously compared with a 3D dataset such as

system which shows the surgeon the posi-

lated. Two measurement principles are now

high investment costs needed to buy the

navigation techniques that are more accu-

a CT model from which the relative position

tion of the medical instruments on three

well established: optical and electromag-

complete system. The second technique of

rate, intuitive and low-cost than comparable

of the instrument to the patient can be read.

dimensional CT or MRT patient data. This

netic tracking. Optical tracking involves an

electromagnetic instrument tracking uses a

systems now on the market. In particular,

By using, so to speak, optical instruments

enables surgeons to navigate accurately to

external stereoscopic camera measuring sys-

magnetic field created by a field generator

the fact that with conventional navigation

for a measuring technique, the scientists are

the operating field where, for instance, they

tem which measures the position of reflec-

to measure the position of a sensing coil on

systems based on individual measurements

simplifying both the handling of the naviga-

can locate a tumor region for a biopsy. For

tor spheres arrayed on the instruments and

the instrument or the operating field. This

of patients and instruments a direct relation-

tion system and the performance of navi-

localization and visualization of the medical

the patient, and which uses these measure-

coil gives data on the position of the medical

ship between the patient and instrument

gated interventions. And since there is no

Your contact

instruments within the field of operation, 3D

ments to calculate the relative position of

instruments and helps to guide them in the

can only be established by means of land-

need to buy external measuring technology,

Manuel Katanacho

CT scans of the patient need to be taken

the instruments to the patient. The major

field of operation. The key disadvantages of

mark registration is widely seen as awkward

substantial savings are also made. The

Phone: +49 30 39006-367

during the preoperative stage.

disadvantages of this technique are that it

this technique lie in its higher inaccuracy and

and technically challenging. What’s more,

Fraunhofer experts are optimistic that this

manuel.katancho@ipk.fraunhofer.de

33

34

Research and Development

FUTUR 1 – 3/2014

Robotics

More Power for the Personnel An Active Jacket for Caregiving Support The daily work of caregivers is above all physically highly demanding. Modern

rect movements and prevent unexpected

research has shown that jobs like helping patients out of bed or helping them to

releases of energy which could be a poten-

move around lead to early signs of wear and tear on the caregivers’ musculoskel-

tial danger for both caregivers and patients.

etal system and thus impair their health. The aim of researchers in the »CareJack«

Accordingly, one of the main precautions

collaborative research project funded by the Federal Ministry of Education and

taken here is to ensure that the scope of

Research BMBF is to engineer a soft robotic assistance system for the upper part

support provided always remains within

of the body in the form of an active jacket. The jacket is supposed to support

the scope of what the caregiver can fully

caregivers in their work and thus to ensure that care-giving services stay fully

master and control. This means that allow-

operational for longer.

ance is always made for a significant part of caregivers own activity, while energy is only released in the sense of an assist-as-needed

►►Active orthoses

avoid the use of bulky power guzzling

is to dynamize all movements like approach-

paradigm to avoid critical stress conditions.

In the »CareJack« project scientists at

motors in order to adapt the periods of use

ing and dealing with patients and thus to let

To this end models of intelligent mechatronic

Fraunhofer IPK collaborate with partners

of the jacket to the service scenarios of out-

the utilizable plus in energy flow into the

concepts are generated which enable the

from industry and research on the develop-

patient care.

system. This energy is then introduced into

rapid optimization of orthosis functionalities

the caregiver’s movement schema where it

without the need for lengthy and costly trial

gives effective controlled support.

and error observation.

►►Use as a teaching

ment of a physical support for caregivers with a very easy to fit active orthosis. These

►►Intermediate power storage

medical aids with a support function can be

The project helps caregivers by ensuring

realized in the form of a stable jacket which

intermediate storage of energy e.g. in

►►Optimizing orthosis functionality

gives active support to movements in the

braked spring mechanisms and its scheduled

The active orthosis must be lightweight,

most frequent care-giving scenarios by

release under an assist-as-needed paradigm.

comfortable to wear, possess mechanical

The concept developed in the collaborative

relieving the strain from the most heavily

Movement, which is the actual main part of

stability, and offer fail-safe operation as

research project also offers the opportunity

acceptance in out-patient and clinical care-

stressed parts of the caregiver’s anatomy.

a caregiver’s activity, is stored in the system

well as energy input, output and recycling.

of using controlled optimized sequences of

giving and subsequently in private care-giv-

The researchers are at particular pains to

as mechanical energy. The underpinning idea

It must impede anatomically critical incor-

movements with monitoring of muscular

ing by family members. In conceptual terms,

stress for learning and teaching purposes in

a high degree of individualization is ensured

vocational and further education. Caregiv-

by the jacket’s modular structure, a dynami-

ers following the principles of motor learn-

cally locking shell and track system which

ing could regularly use the haptic support

allows for comfortable use of the support

The turning and lifting of patients is a physically highly demanding activity for caregivers.

and learning artifact

The construction principle of the »CareJack« soft robotic jacket.

provided by the system to learn correct ways

system even in situations where users fre-

CareJack Project Partners

of movement. Particularly in the professional

quently change. The proven efficiency of

–– Arbeiter-Samariter-Bund KV Lübben

environment of out-patient and in-patient

the orthosis will be demonstrated in three

–– Fraunhofer IPK

healthcare, such a non-bureaucratic training

stage tests in a controlled clinical care-giving

–– Fraunhofer Institute for Reliability and

option would have the effect of increasing

environment and in an outpatient care-giv-

efficiency and reducing costs. Higher effi-

ing environment. Its suitability as a teaching

–– iXtronics

Microintegration IZM

ciency and lower costs are driven by inte-

and learning artifact for the acquisition of

–– Klinikum Stadt Soest

grated miniaturized control elements such

optimal movements will be demonstrated in

–– O.T.W.-Orthopädietechnik Winkler

as biocompatible EMG electrodes and rotary

a clinical care-giving environment.

–– Reha-Zentrum Lübben

position / force sensors as well as by signal

–– Würth Elektronik

preprocessing by flex and rigid-flex PCBs integrated in the carbon fiber composite material of the orthosis. The modular design of system components also contributes to

Your contact

the jacket’s lightweight engineering concept

Henning Schmidt

and to cost-efficiency in manufacturing.

Phone: +49 30 39006-149

These two factors will accentuate its market

henning.schmidt@ipk.fraunhofer.de

35

36

Research and Development

FUTUR 1 – 3/2014

Knowledge Management

Reissued The »Intellecutal Capital Statement – MADE IN GERMANY« Toolbox and User Guide Intangible assets are difficult to quantify but essential to entrepreneurial success.

The »Intellectual Capital Statement – Made in Germany« management method developed by Fraunhofer IPK serves for the systematic identification and evaluation of the intellectual assets held by a company and for the planning, controlling and documentation of development measures. The newly reissued Intellectual Capital Statement Toolbox 2.0 is the centerpiece of the method and links up to the success of its predecessor which has been ordered by over 200,000 companies since publication. The new version takes account of current research findings and advances in methodology which also serve to enrich the revised and updated version of the Intellectual Capital Statement User Guide 2.0 as well as add-on modules for strategy development, on-going intellectual capital reporting and measures management.

Technology, the Intellectual Capital State-

future workshops with a view to identifying

recommends regular repetition of the Intel-

ment is now established across Germany

needs for action and the specific require-

lectual Capital Statement.

and the whole of Europe. With the »Intel-

ments of townships and city districts in

lectual Capital Statement – Made in Europe«

terms of enhancing the regional value cre-

IPK experts now offer tried and tested user-

ation chain and feeding them into a regional development strategy.

Intellectual Capital Statement, this guideline

The Intellectual Capital Statement Toolbox is

»Measures« work stage in which measures

tors specially tailored for the achievement

a software which aids companies to identify

derived for enhancing Intellectual Capital

of strategic goals be planned for in work-

►►The role of the ICS moderator

structural gaps in knowledge and develop

can be documented in greater detail and

shops, but issues of particular bearing on

To ensure consistent quality in the practi-

oriented methods for the assessment and

hidden knowledge assets. In eight simple

over a longer period of time.

the evaluation process can also be identified

cal running of Intellectual Capital Statement

control of Intellectual Capital to companies

and given a definite form.

methods, Fraunhofer IPK in association with

in the European SME sector. With the estab-

the Fraunhofer Academy and the Intellec-

lishment of a national »Intellectual Capital

stages it identifies the intangible assets of a company from the areas of human capital,

►►ICS Guidelines 2.0 and supplementary guidelines

On the other, the supplementary guideline

tual Capital Statement working group offer

Center« they also wish to promote broader

The Intellectual Capital Statement Guide-

on »Management of Measures« is focused

a course of training as a certified ICS mod-

uses of the methods and implement inter-

as successful communication, product inno-

lines describe the procedure for drawing up

on the planning, realization and controlling

erator. The multi-stage program offers a

national standards and structures for the

vation and good customer relationships.

an Intellectual Capital Statement and offer

of measures derived from the Intellectual

unified acknowledged certification model

assessment, measurement and management

structural capital and relational capital and evaluates them. These include such assets

By supplementing the traditional business

organizations, in particular companies in the

Capital Statement. On the interface of mea-

for the systematic control and communica-

of Intellectual Capital. The first experiences

report and its exclusive focus on financial

SME sector, useful tried and tested ways

sures implementation the Intellectual Capital

tion of soft success factors, and trains can-

have been made in a variety of countries

aspects with soft factors that previously

and means of implementation. The reis-

Statement can be used as an instrument to

didate ICS moderators in the proper use of

including Malaysia and Brazil.

received scant attention, the Intellectual

sue of Guidelines 2.0 »Intellectual Capital

control transformative measures as it peri-

its methods and add-on modules in com-

Capital Statement ICS offers the company

Statement – Made in Germany« picks up

odically assesses the key factors of success

pliance with quality standards. On top of

an in-the-round picture of its organization

on the amendments made in the reissue of

such as competence, structures and external

this, over 30 ICS moderators are now orga-

and can stimulate improvement in critical

the Intellectual Capital Statement Toolbox

relations. The changes which thus become

nized in the Bundesverband Wissensbilan-

The concept of Intellectual Capital has thus

areas. Novel visualizations such as time

2.0 and in three places refers to advanced

visible offer information about the success

zierung (National Association of ICS Mod-

far been researched and tested specifically

series presentations of the Intellectual Capi-

developments of methodology which it elab-

of the measures initiated.

tal evaluation, text field formatting and over-

orates and illustrates with practical examples

views in tabular form support comparisons

in separate supplementary guidelines.

of Intellectual Capital over periods of time

►►Intellectual Capital on the regional level

erators – BVWB) with a view to ensuring the

with regard to enterprise. But how can Intel-

quality of reporting of Intellectual Capital

lectual Capital be defined and evaluated in

The third new supplementary guideline

Statements and of promoting broader use

a much broader context such as the regional

»Continuous Intellectual Capital Reporting«

of the method.

level? What role might be played alongside

Your contact

enterprise by stakeholder groups from cul-

Sven Wuscher

ture, politics, research and education will be

Phone: +49 30 39006-303

shown by the first tests taking place in 2015

sven.wuscher@ipk.­fraunhofer.de

and optimize evaluation options for overall

On the one hand, the »Developing Strate-

highlights the changes that have taken place

better reporting.

gic Goals« guideline shows companies how

in the execution of the project since the time

to identify their overarching corporate aims

when the first Intellectual Capital Statement

Alongside documentation aids and visual-

and objectives, and how to plan the strategic

was made. With a view to controlling and,

Originally started as a project in the »Fit für

in the »Crowd Production« project in the

izations, further innovations have also been

direction in a structured way with participa-

if necessary, realigning the continual review

den Wissenswettbewerb« (Fit for the Knowl-

region of Bischofswerda in Germany. This

Erik Steinhöfel

introduced such as direct export of graphics,

tion of key figures in the company. Working

of the business model and the success of

edge Competition) initiative, and funded

project links the concept of Intellectual Capi-

Phone: +49 30 39006-371

color configuration and an extension of the

from this basis, not only can individual fac-

the measures initiated in the context of the

by the Federal Ministry of Economics and

tal Statements with that of moderated

erik.steinhoefel@ipk.­fraunhofer.de

►►Establishing a national Intellectual Capital Center

37

38

Interview

FUTUR 1 – 3/2014

Smart Robotics Solutions for Flexible Production Whether it is robot-assisted machining with industrial robots or human-robot cooperation in the assembly line factories of the future, one name is bound to appear in all the major European collaborative research projects on robotics – Comau. Over the years this Italian company and Fraunhofer IPK have built a close partnership in robotics development which first began in the early 1990s with joint work for the European Space Agency ESA. FUTUR talked to Stefano Ocleppo, the new marketing manager for Germany, about present tasks and future challenges in robotics.

FUTUR: Signor Ocleppo, you have only

the one that brings the highest standard

recently switched from Comau Italy to Germany – what differences strike you between the German and Italian robotics market?

tion for production and its philosophy to

give more flexibility to the production line

was recognized by our customers as the best

of productivity, while as a part of one of

for future retooling and enable the design

option available on the robotics market and,

provide plug and play integrated effective

the worldwide largest line builders, Comau

of high density robotics cells with significant

as an unexpected side effect, this solution

robot packages inclusive of tools, Comau

Robotics is driven by the need to provide

saving of floor space. Similar considerations

was adopted by a number of schools and

belongs to those actors that are still strongly

manufacturing equipment with certain

could be described for the development of

research institutions so that we are now

investing in research to reach a 100 percent safety of robotic applications.

Ocleppo: The most evident is for sure the

installation costs and timing. Translated in

fully integrated application packages and

counting hundreds of installations. For this

size. Despite the fact that the German and

terms of robotics products, our philosophy

dedicated robots such as those for the

reason there were no doubts to extend the open version to the C5G, too.

About Stefano Ocleppo Following a master's degree in Engineering at the POLITECNIC of TURIN in 1991 and before

FUTUR: Your development department in

starting to work for the automation provider

Turin works in close collaboration with our

Comau, Stefano Ocleppo developed his profes-

FUTUR: Human-robot cooperation has

own robotics experts. What advantages do

sional background in two other companies: De

been the key focal point of research and

you gain through collaboration with external

Longhi, the Italian producer of house applian-

1000 mm from robot wrist, or machines

development for decades now. What

research partners?

ces, where he was responsible for the product

able to exceed the benchmark in their cat-

trends do you see here in terms of indus-

eral thousands of pieces, can be taken as

egory of speed performances such as the

trial applications?

an example to put in evidence the applica-

high speed RACER robot.

Italian robotics market developed in the

expresses itself through the design of dedi-

handling in the press shop equipped with

same period, the German one took advan-

cated machines and application packages

double motor on axis one, or those for the

tage of the presence of a larger number of

with extremely competitive life cycle costs

remote laser welding where the laser beam

big car makers. The robot demand gener-

and overall equipment efficiency. Our hol-

is focalized through the robot arm up to

ated by some of the world's biggest auto-

low wrist smart solution for spot welding,

mobile producers pushed the growth of the

running since the end of the 1990s in sev-

German robotics market up to four times the size of the Italian one. The other difference is the shrinkage of the Italian internal

tion of the above described philosophy. The

demand by robot end users due to limited

revolutionary patented design of a mechani-

compliance to technical and quality standards,

Ocleppo: The vocation of Comau to inno-

and the Swedish SAB WABCO, now acquired

vation has always brought our company to

by the French FAIVELEY TRANSPORT, supplier

Ocleppo: Yes, the man-robot cooperation

work very close to the best research institu-

of brakes systems for train companies, where

FUTUR: With its C4GOpen and C5GOpen,

has been at the center of the R&D of most

tions in the world as a way to get access to

he started as Quality Assurance Manager and

access to credit for small and medium-sized

cal articulated arm able to host all cables

Comau is one of the very few vendors of

robotics players for a long time and Comau

the most up-to-date knowledge and a way

ended up seven years later as Operation Mana-

companies and consequent investment post-

and pipes for the resistance welding appli-

open control systems on the market. What

belongs to those that were deeply involved

to get fresh ideas from teams having a dif-

ger. These ten years of experience in products

ponement or cancellation in the last five to

cation is bringing to the end user of our

is the reasoning behind this?

in it since the earliest stage. The Comau

ferent perspective compared to the more

and processes in a mass production company

six years. The reduction of the internal mar-

robots a significant number of direct and

expectation for the future of the man-robot

utilitarian vision of the industrial R&D.

as well as the experience in quality, enginee-

ket is compensated in number of sold units

indirect efficiency. The protection given by

Ocleppo: The push to introduce an open

cooperation is its large extension to most of

Besides the large number of disciplines and

ring and operations at a system supplier gave

by the strong export capacity of the Italian

the mechanics to the cables reduces dra-

version of the Comau controller comes from

the known industrial applications. Unfortu-

technologies that our Research and Devel-

him knowledge and expertise that he brings

integrator, but determines a profit reduction

matically the maintenance cost in a body

the propensity of our company to work

nately, it might still take a while. Although

opment must master for the development

as added value to Comau's customers in his

for the Italian robot producers which have to

shop and increases the technical availability

with very advanced integrators, research

the state of the art robots have reached full

of our high-tech products, there are also

current position of Business Development and

support the line builder in its competitions

of the equipment. But these are only some

centers and machine builders. As we got

safety standards and although we already

very different fields with which Comau

Sales Manager for Robotics and Service at

and installations abroad more often.

of the benefits. The absence of unpredict-

aware of the need of these players to have

see on the market small »safe« machines

enters into contact as a provider of process

Comau Deutschland GmbH.

able cable positions in combination with a

their own motion controlled solution, we

cooperating with humans for some service

solutions to a broad range of industries.

FUTUR: What is the philosophy behind

very high accuracy of this robot enables a

decided to catch the opportunity to pro-

applications, the ready-to-install robotized

Only the cooperation with structured and

Comau’s robot-assisted SMART solutions?

100 percent off-line programming that gives

vide them with an open controller in order

man-machine applications for production

strong organizations such as F­ raunhofer IPK

enormous advantages to the line builder at

to bind our name and strengthen the rela-

are not yet available on the market and the

gives us the opportunity to develop those

Your contact

Ocleppo: As part of a big manufacturing

installation and commissioning time and to

tionship with partners with high inclination

end users must still carry at their own charge

tested, proven, sustainable and distinctive

Stefano Ocleppo

group the dominant philosophy behind the

the end user at every start of production of

to research and development of distinctive

the risk assessment of the installation. Due

solutions that must give that competitive

Phone: +49 6103 3103512

development of our integrated solution is

a new model. Besides, such characteristics

solutions. Very soon this value proposition

to its exclusive focus on industrial applica-

advantage requested by our customers.

stefano.ocleppo@comau.com

39

40

Company Profile

Machine Portrait

Schaudt Mikrosa

Selective Laser Melting

Schaudt Mikrosa is living proof that quality is paramount and that only those

The SLM 250HL machine from SLM Solutions was installed at Fraunhofer IPK in

who deliver absolutely impeccable products can hope to survive in the competi-

December 2009. It is used for industry-commissioned R&D work on selective laser

FUTUR 1 – 3/2014

tive global marketplace. Camshaft and crankshaft grinders under the SCHAUDT

melting and its customers come mainly from the engine and turbine construction

brand name and centerless grinding machines under the MIKROSA brand are

and mold and tool-making industries.

the areas of expertise of this global player from Leipzig. The historical, fully modernized factory in the Leipzig district of Plagwitz produces premium range, maximum precision grinding machines with grinding accuracies within the barely measurable 0.1 micrometer range.

►►Functions and goals In 2011 the company merged the two tra-

–– Generative manufacturing of highly

ditional brands SCHAUDT and MIKROSA

complex component geometries

under one roof of its plant in Leipzig. »Con-

–– Process design for the processing

centrating all our production and adminis-

of innovative materials

tration activities on one site was the logical

–– Parameter studies for optimization of

consequence of ever closer collaboration

component characteristics

between Stuttgart and Leipzig«, explains

–– Processing of high temperature alloys

Paul Kössl, director of sales. The individ-

(Ti- and Ni-based alloys)

ual product lines CamGrind, CrankGrind,

for energy and aerospace technology

FlexGrind und KRONOS will now be pro-

–– Processing of highly corrosion-resistant

duced more efficiently and rapidly, each

and lightweight titanium for prototypes

in its own bay. »What we are particu-

for the medical technology sector

larly good at« Kössl continues, »is linking machines, automation components and process technology in a highly productive grinding system.« Since its restructuring all systems are set

The MTT Selective Laser Melting System SLM 250H Manufacturing hall of the Schaudt Mikrosa plant in Leipzig

►►Materials

►►Facts and Figures

for growth in this Saxony-based company whose tradition stretches back to the year 1878 when Kirchner & Co., a wood work-

global network of branch offices and sales

shaft main and pin bearings. For the special-

ing machine manufacturer was established

agents, the Group is strongly positioned

ists in camshaft grinding moving on to the

on the same site. Since the 1990s the com-

and close to its customers. This means that

crankshaft, the heart of every engine, was

pany has been part of the UNITED GRIND-

Schaudt Mikrosa can offer a diversity of

only the next logical step. Here the highest

ING Group, the world’s leading provider of

products and services that are particularly

quality and narrow tolerance are of truly

machines, applications and services for hard

appreciated and esteemed in the automo-

paramount importance. As Paul Kössl says,

finishing. With its eight premium brands and

tive sector. As Paul Kössl comments, »In

»The CrankGrind now puts us in a position

practically every German car there is a cam-

to support OEMs and vendors seeking to

shaft ground by one of our machines«. Yet

meet the ever higher requirements for lower

apart from the automotive industry, many

emissions in combination with fuel-saving

Contact

other branches like the medical technology

low-maintenance engines«. It is an invest-

Schaudt Mikrosa GmbH

sector and the tool and bearing industries

ment in the future and not just for Schaudt

Saarländer Straße 25

are also customers of the company.

Mikrosa alone.

04179 Leipzig

Build Chamber X, Y, Z

250 mm x 250 mm x 350 mm

Laser

ND:YAG-Laser, 400 W

Operational Beam Focus

70 … 300 µm

Layer Thickness

70 … 300 µm

Particle Size

10 … 65 µm

Build Speed

5 … 20 cm³/h

Porosity / Thickness

0,03 % / 99,97 %

Tolerance

± 50 µm (x, y, z)

Roughness

Rz_horizontal = 56 µm Rz_vertical = 72 µm

–– Stainless Steel (1.4016, 1.4404, 1.4410) –– Tool Steel (1.2709, 1.2344) –– Titanium (TiAl6V4, TiAl6Nb7) –– Aluminum (AlSi10Mg, AlSi12Mg) –– Nickel-based alloy (Inconel 625, 718)

Your contact

Phone: +49 341 4971-0

The latest development from SCHAUDT is

sales@schaudtmikrosa.com

the CrankGrind, a high precision cross-slide

Phone: +49 30 39006-269

grinding machine for the grinding of crank-

robert.kersting@ipk.fraunhofer.de

www.schaudtmikrosa.com

Robert Kersting

41

42

Events and Dates

FUTUR 1 – 3/2014

The Number One Export Hit

Cooperation with Brazil Continues

Canadian Federal Industry Learns about the Fraunhofer Model

New Agreement with SENAI till May 2019

In mid-June, Deputy Minister Knubley from Canada visited

Together with Brazil’s National Service for Industrial Training, SENAI,

Brazil have been officially opened. According to SENAI, the institutes

Fraunhofer IPK to learn about work at Fraunhofer and the TU Ber-

Fraunhofer IPK is planning and building 24 institutes for applied

acquired about 35 million Euro in applied R&D projects in 2014. On

lin. Accompanied by Commercial Counselor Richard Tarasofsky and

research across Brazil. The project has been running since June

July 28, future directors of SENAI institutes took a management

Dr. Bruno Wiest, the Science and Technology Trade Commissioner

2012, and on May 21, 2014 a new agreement was signed extend-

training course at Fraunhofer IPK. And at a meeting between Chan-

at the Canadian Embassy in Berlin, he was first of all given insights

ing work for a further five years.

cellor Angela Merkel and the President of the Federative Republic of Brazil, Dilma Rousseff, that took place on June 15 in Brasília, instal-

into the structure and financing of the Fraunhofer-Gesellschaft. The address given by IPK executive director Professor Uhlmann then

Fraunhofer IPK is advising its Brazilian partner on the strategic plan-

lation of the reference centers by Fraunhofer IPK and SENAI was

gave the guests more details about the Production Technology Cen-

ning and implementation of research institutes, development of a

a topic that figured on the bilateral agenda. Rousseff praised the

ter and various national – and international – research projects. A

central agency in Brasília to support and assist them and on imple-

excellent work done by the Fraunhofer-Gesellschaft in the structur-

detailed tour of the Center’s testing fields made stops at the stations

mentation of an evaluation system for the existing research net-

ing of research and innovation institutes in Brazil while Chancellor

for »Laser Powder Deposition Welding«, »Magnetic Impulse Form-

work. IPK has so far brought in a further 15 Fraunhofer Institutes

Merkel declared: »We should make special efforts to consolidate

as technology experts for work on the SENAI project. On July 1,

this strategic partnership between our two countries«.

ing«, »Dry Ice Blasting«, »Robot-assisted Machining Strategies« and the Application Center for Microproduction Technology. There are already a number of fields in which future collaboration with Canada would be feasible – the Joining and Coating Technology division,

Photo Caption: From left to right: Dr. Bruno Wiest, Science and Technology Trade Commissioner, Canadian Embassy, Professor Eckart Uhlmann, Executive Director, Fraunhofer IPK, Deputy Minister Knubley and Dr. Dirk Oberschmidt, Head of Application Center for Microproduction Technology

for instance, has already formulated project proposals for collaboration with enterprise and institutions in the province of Alberta.

2014 an IPK project bureau was opened in Brasília, headed by Dr. Markus Will, to serve as a regional branch office. The aim of the new bureau is to strengthen the role played by IPK in BrazilianGerman collaboration in the field of applied research. This is a role

Your contact

Your contact

Fraunhofer IPK is well suited to play as it combines expertise from

Prof. Dr.-Ing. Holger Kohl

Steffen Pospischil

German and European research projects with a wealth of experi-

Phone: +49 30 39006-233

Phone: +49 30 39006-140

ence from international projects for the development of regional

holger.kohl@ipk.fraunhofer.de

steffen.pospischil@ipk.fraunhofer.de

innovation systems in newly industrializing countries.

Fraunhofer IPK Project Office Brazil

How to Turn Intellectual Capital into Business Success Brazilian-German Innovation Congress 2014 main aspects of the Brazilian-German Innovation Congress attracted more than 1,500 participants from December 1 to 3, 2014 to the World Trade Center in São Paulo. As part of the Open Innovation Week organized by the Open Innovation Center Wenovate, the congress brought together high-level representatives of industry and applied research, entrepreneurs and innovation facilitators from both Brazil and Germany. Organized by Fraunhofer IPK and the National Service for Industrial Training SENAI, it featured speeches of Prof. Jefferson Gomes, SENAI, Luís César Verdi, SAP, and Prof.

Holger Kohl, Fraunhofer IPK. The political view on innovation was Ministry of Education and Research BMBF, supported by best-practice examples of applied research presented by Brazilian and German

Innovation Fair: Representatives of Fraunhofer IPK, ENAS, UMSICHT, Fraunhofer Project Center for Innovations in Food and Bioresources, and Fraunhofer Liaison Office (Copyright: José Paulo Lacerda/CNI)

research institutes. A workshop on Intellectual Capital Statements gave insights into the management of intangible assets. Innova-

Your contact

tive congress concepts such as the Innovation Race, where several

Prof. Dr.-Ing. Holger Kohl

teams created ideas within 72 hours, 100 competing startups and

Phone: +49 30 39006-233

an Innovation Fair with several Fraunhofer institutes presenting their

holger.kohl@ipk.fraunhofer.de

latest R&D built an inspiring environment.

Dr.-Ing. Markus Will Phone: +55 61 3317-8918

budget of a further 6 million Euro. To date, four SENAI institutes in

markus.will@ipk.fraunhofer.de

Signing the agreement for further cooperation: (from left to right) Professor Holger Kohl, Professor Eckart Uhlmann (both Fraunhofer IPK), Professor Gustavo Leal, Director of Operations, SENAI and Professor Jefferson Gomes, Executive Manager of Innovation and Technology, SENAI

Great speeches, networking and innovative congress concepts – the

presented by Dr. Matthias Frattini representing the German Federal

Project funding for the first two years comes to 2.2 million Euro.

The new agreement covering work till 2019 makes provision for a

www.bg-innocong.com

43

44

Events and Dates

FUTUR 1 – 3/2014

A Sino-german Model Project

German High Tech Champion 2014 from Fraunhofer IPK

Fraunhofer IPK Signs Framework Agreement for Collaboration with Zhongde In the south China province of Guangdong the People’s Republic’s

Award for a Novel Transport Concept for Logistics Providers

sustainability. For German companies too, establishing a foothold in

first ecological city is now being built at the gates of the city of

the ecological metal city is a good opportunity to enter the rapidly

Jieyang. The »Sino-German Eco Metal City« is a model project for

growing markets of the People’s Republic.

state of the art metal machining and working in harmony with the needs of mankind and nature. 150,000 people will live and work

Fraunhofer IPK’s role is to support vocational education programs

in the new city. The project’s initiator is the ZhongDe Metal Group,

and assist in the building of the technical infrastructure as well as

an association of 701 regional metal companies. Fraunhofer IPK in

to promote cooperation between metal industry companies in the

collaboration with RSBK strategic consulting founded by former

two countries. After the signing of the framework agreement last

minister of defense Rudolf Scharping is helping to lead this Sino-

November, the next move is to identify joint projects with a view to

German project to a successful future.

supporting local enterprise. Furthermore, delegations from ZhongDe will visit Germany, while experts from Fraunhofer IPK will also par-

30 percent of all Chinese metal and steel production is concentrated

ticipate twice a year in working sessions in Jieyang.

in Guangdong province. After the rapid successful expansion of this industry sector, attention has now turned to improving its technical and ecological aspects. Plans for building the city have been at par-

The electric lead vehicle and transport units of the novel »MicroCarrier Urban Vehicle« (left), the MicroCarrier prototype in hand-driven operational mode (right)

ticular pains to ensure that sufficient space is given for woods and lakes alongside room for living and working and university build-

Your contact

On behalf of the whole development team, Fraunhofer IPK’s Mat-

ship between the force exerted by the operator and the speed and

ings. Cooperating with German partners to address such challenges

Prof. Dr.-Ing. Holger Kohl

thias Brüning received the award for »German High Tech Cham-

acceleration of the vehicle. Furthermore, when vehicles are joined

seemed an obvious move as Germany enjoys an excellent reputation

Phone: +49 30 39006-233

pion 2014« in the category »Urban Distribution«. His submission

together to form a train, a new steering technology enables each

in China in terms of its technology, environmental engineering and

holger.kohl@ipk.fraunhofer.de

was the concept and realization of the »MicroCarrier Urban Vehicle

vehicle to precisely follow the track of the preceding transport unit.

MCUV« , a single-axle, hand-driven, electric motor goods transport

These technologies have been realized with special regulation and

vehicle for logistics providers. The MicroCarrier was developed in

estimation algorithms with minimal need for sensors to facilitate

a number of research projects headed by Werner Schönewolf. The

low-cost robust manufacturing of the vehicles.

On 22 November 2013 Fraunhofer IPK, RSBK and ZhongDe signed a framework agreement in Jieyang, China: Professor Dr. Holger Kohl (middle.), Rudolf Scharping, former Minister of Defense (left) and Wu Kedong, President of the ZhongDe Metal Group (right).

MicroCarrier has its own built-in system for balancing and can be operated intuitively like a standard sack cart with very little effort.

The GHTC-Award® is part of the »International Research Marketing«

The award which comes with an endowment of 10,000 euros was

consortium project operated jointly by the Alexander von Humboldt

given on April 3, 2014 in Paris at the SITL Europe logistics trade show.

Foundation, the German Academic Exchange Service, the German

Matthias Brüning’s R&D work aimed to introduce a new logistics

Research Foundation and the Fraunhofer-Gesellschaft. The aim of

concept that would raise the efficiency and sustainability of down-

the project is to enhance the reputation of Germany as a place for

town deliveries in urban areas. Use of diesel engine delivery trucks

excellence of research both at home and abroad, and to sharpen its

– the standard thus far – has a negative impact on flow of traffic,

profile on the global science market. All measures initiated by the

quality of air and level of noise. Not just the emissions from the

project form part of the »Promoting Germany as a Land of Inno-

diesel engines of these delivery trucks have a negative effect, but

vation and Research« initiative funded by the Federal Ministry of

also those from vehicles forced to accelerate to pass them when

Education and Research under the »Research in Germany« portal.

they are doubled parked.

For more information, see:

www.research-in-germany.de

The MicroCarrier is the realization of a novel logistics concept based on two different ways of using the vehicle. It can equally be used for the hand-driven delivery of packages on foot and in combination with an electric lead vehicle as a variable chain of narrow MicroCarrier transport units. Such functionality is built on three fundamental technological innovations. The first innovation is an adaptive balance regulator which during loading and unloading operations

Your contact

adapts the vehicle to changing shifts of weight and thus enables it

Dipl.-Ing. Matthias Brüning

to remain stable while standing still. The second innovative technol-

Phone: +49 49 314-26858

ogy is for regulation of maneuverability which regulates the relation-

matthias.bruening@ipk.fraunhofer.de

45

46

Events and Dates

FUTUR 1 – 3/2014

Award-winning

High Tech and Jewish History

The »ORBIT« Project Wins »GHTC® – The German High Tech Champions Award« in Medical Imaging

Cooperation between Fraunhofer IPK and the Moses Mendelssohn Center

The ORBIT research project has won the GHTC® – the German High

In recognition of this development Professor Keeve has now been

The Fraunhofer Institute for Production Systems and Design Technol-

Tech Champions Award 2014 in the category »Medical Imaging«.

honored with the GHTC Award – the German High Tech Champi-

ogy IPK and the Moses Mendelssohn Center for European Jewish

to open up new horizons and help us access Jewish history in a

ORBIT realizes a groundbreaking imaging concept in which X-ray

ons Award 2014 in the category »Medical Imaging«. Funded by the

Studies MMZ have announced plans to work together. The IPK will

completely new and deeper dimension.«

source and X-ray detector are decoupled from one another in their

Federal Ministry of Education and Research BMBF, the ORBIT project

employ their cutting edge technology based on the latest methods

movement during X-ray acquisition and thus only minimally impede

has already won the BMBF Medical Technology Innovation Award

of pattern recognition and image processing to virtually recon-

Dr. Bertram Nickolay, Head of Security Technology at Fraunhofer IPK

free access to the patient.

®

prospect of engineers and humanities scholars working together

in 2007 and 2010. The GHTC – the German High Tech Champions

struct and access destroyed and damaged documents and objects.

adds: »Our successes in the virtual reconstruction of torn Stasi docu-

Award was presented on December 2, 2014 at the »RSNA 2014 –

In this way, cultural heritage treasures will be able to be restored

ments form the cornerstone for the projects dealing with damaged

and preserved.

or destroyed archives, and making documents accessible worldwide

®

In complex surgical procedures or acute care for patients with mul-

100th Scientific Assembly and Annual Meeting of the Radiological

tiple trauma, surgeons control the interventions they are about

Society of North America« in Chicago. After the awards ceremony,

to make through use of X-ray images. This is best done with 3D

the winners had the opportunity to meet potential business partners.

exciting challenge to be using many of our technologies, usually

images as these give exact spatial representations of the insides of

With over 26,000 attendees the annual meeting of the RSNA is one

developed for industrial use, to preserve Jewish cultural heritage.«

a patient’s body. Yet thus far acquisition of such images has come

of the world’s biggest congresses of radiologists. And as Professor

at the price of restricted patient access which presents serious risks

Keeve commented, »ORBIT is the world’s first open 3D X-ray system.

A total of nine project proposals were agreed upon:

We are grateful to the BMBF and our participating project partners

–– Accessing and evaluation of damaged and destroyed frag-

particularly when it comes to acute care.

through digitalization. For us engineers, it is a very special and

for the support they have given us in developing this innovation, Against this backdrop, Fraunhofer IPK is developing ORBIT, an intra-

and proud that we can present it at the 100th annual meeting of

operative 3D X-ray system which allows access to the patient dur-

the Radiological Society of North America to such a broad audience.

ments of the Fundación IWO, Buenos Aires –– Digitalization of the Strashun Library in Vilnius within the framework of an EU project initiative

ing the imaging process. Professor Erwin Keeve and his team use

We intend to develop ORBIT still further within the framework of

–– Development of a data bank on German-Jewish history

state of the art robotics to realize a novel image recording concept

the Medical Technology Solutions for Multimorbidity promotion

–– Digitalization and cataloguing of Prague’s Literary House of

whose technology can be permanently installed in the operating

program derived from the proposals for the National Strategic Pro-

table, which means that only a few steps are needed before the

cess Innovation in Medical Technology«.

German-Language Authors –– Development of a data bank with special archival technologies

system is operational. In ORBIT the robot-driven X-ray source moves

allowing searches on the books burned and authors banned

over the operating table while the X-ray detector has a specially

On November 13 in Düsseldorf, a GHTC® sneak preview gave selected

developed kinematics system which can be attached to the operat-

representatives of German industry an exclusive preview of the win-

ing table’s column or to the actual tabletop. During recording the

ners. The GHTC® Award is part of the »International Research Mar-

source and detector move independently from one another and

keting« consortium project operated jointly by the Alexander von

thus only minimally impede access to the patient.

Humboldt Foundation, the German Academic Exchange Service,

ORBIT in the emergency trauma room.

Graphic © Fraunhofer IPK, Design: Jonas & der Wolf, Berlin

in the Nazi period –– Establishment of a picture archive of German Jewry Severely weather-beaten Jewish headstones whose inscriptions, thanks to intelligent mobile tools, should be made legible again.

–– Initiative on tracing stolen or looted art: further development of the Fraunhofer art tracing system for mobile provenance research

the German Research Foundation and the Fraunhofer-Gesellschaft.

The MMZ conducts interdisciplinary basic research with a focus on

–– Usage of pattern recognition technology to automatically

The aim of the project is to enhance the reputation of Germany as

the history, religion and culture of Jews and Jewry, with a particu-

trace right-wing extremist and anti-Semitic symbolism

a place for excellence of research both at home and abroad, and

lar emphasis on processing regional and local history. Numerous

in the digital world

to sharpen its profile on the global science

requests from Jewish archives and museums from all over the world

market. All measures initiated by the project

have proven the great need for the implementation of the IPK’s

Specific plans have already been drawn up for the

form part of the »Promoting Germany as a

reconstruction technology. On this basis, the project partners have

–– Development of intelligent, mobile tools to make indecipher-

Land of Innovation and Research« initiative

developed an interdisciplinary project initiative on the restoration

funded by the Federal Ministry of Education

and preservation of Jewish cultural heritage and legacy. Further-

and Research under the »Research in Ger-

more, the partnership will be supplemented by the current topics

many« portal. For more information, see:

of tracing looted or stolen art and right-wing extremist symbolism

www.research-in-germany.de

in the Internet.

able epitaphs at Jewish cemeteries legible once again.

Your contact Dr. Bertram Nickolay Phone: +49 30 39006-201

Your contact Prof. Dr. Erwin Keeve

Prof. Dr. Julius H. Schoeps, Director of the Moses Mendelssohn

bertram.nickolay@ipk.fraunhofer.de

Center for European Jewish Studies explains: »The use of the cut-

Phone: +49 30 39006-120

ting edge technologies, which we are developing together with

Dr. Elke-Vera Kotowski

erwin.keeve@ipk.fraunhofer.de

our colleagues at the Fraunhofer Institute to fit our specific needs,

Phone: +49 331 28094-12

www.research-in-germany.de/ghtc

signals a quantum leap in our research. I am very pleased by the

kotowski@uni-potsdam.de

47

Profile Production Technology Center PTZ Berlin The Production Technology Center PTZ Berlin comprises of the Institute for Machine Tools and Factory Management IWF of the Technical University of Berlin and the Fraunhofer Institute for Production Systems and Design Technology IPK. The PTZ develops 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.

The PTZ is equally committed to making its own contributions to applicationoriented basic research and to developing new technologies in close collaboration with industry. The PTZ works together with its industry partners to transform basic innovations born in research projects into fully functional applications.

With the methods and techniques we develop or improve, we offer our partners comprehensive end-to-end support from product development and fabrication through to product recycling. This also includes the conception of means of production and its integration in complex production facilities, and innovation of all corporate planning and controlling

Your Contact at the PTZ Berlin Corporate Management Prof. Dr.-Ing. Holger Kohl Phone +49 30 39006-168 holger.kohl@ipk.fraunhofer.de Virtual Product Creation, Industrial Information Technology Prof. Dr.-Ing. Rainer Stark Phone +49 30 39006-243 rainer.stark@ipk.fraunhofer.de Production Systems, Machine Tools and Manufacturing Technology Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Phone +49 30 39006-101 eckart.uhlmann@ipk.fraunhofer.de Joining and Coating Technology (IPK) Prof. Dr.-Ing. Michael Rethmeier Phone +49 30 8104-1550 michael.rethmeier@ipk.fraunhofer.de Joining and Coating Technology (IWF) Prof. Dr.-Ing. Rainer Stark (komm.)

Phone +49 30 314-25415 rainer.stark@tu-berlin.de Automation Technology, Industrial Automation Technology Prof. Dr.-Ing. Jörg Krüger Phone +49 30 39006-181 joerg.krueger@ipk.fraunhofer.de Assembly Technology and Factory Management Prof. Dr.-Ing. Günther Seliger Phone +49 30 314-22014 guenther.seliger@mf.tu-berlin.de Quality Management, Quality Science Prof. Dr.-Ing. Roland Jochem Phone +49 30 39006-118 roland.jochem@ipk.fraunhofer.de Medical Technology Prof. Dr.-Ing. Erwin Keeve Phone +49 30 39006-120 erwin.keeve@ipk.fraunhofer.de

processes.

Fraunhofer Innovation Cluster LCE Life Cycle Engineering Dr.-Ing. Martin Bilz Phone +49 30 39006-147 martin.bilz@ipk.fraunhofer.de Next Generation ID Prof. Dr.-Ing. Jörg Krüger Phone +49 30 39006-183 joerg.krueger@ipk.­fraunhofer .de

Fraunhofer Alliances

Competence Centers

AdvanCer Hochleistungskeramik Christian Schmiedel Phone +49 30 39006-267 christian.schmiedel@ipk.­fraunhofer.de

Additive Manufacturing Dipl.-Ing. André Bergmann Phone +49 39006-107 andre.bergmann@ipk.­fraunhofer.de

autoMOBILproduktion Dipl.-Ing. Eckhard Hohwieler Phone +49 30 39006-121 eckhard.hohwieler@ipk.­fraunhofer.de

Application Center Microproduction Technology (AMP) Dr.-Ing. Dirk Oberschmidt Phone +49 30 39006-159 dirk.oberschmidt@ipk.fraunhofer.de

Additive Manufacturing Dipl.-Ing. Benjamin Graf Phone +49 39006-374 benjamin.graf@ipk.­fraunhofer.de

Benchmarking Dipl.-Wirt.-Ing. Oliver Riebartsch Phone +49 30 39006-262 oliver.riebartsch@ipk.­fraunhofer.de

Numeric Simulation of Products, Processes Dipl.-Ing. Raphael Thater Phone +49 30 39006-375 raphael.thater@ipk.­fraunhofer.de

Electromobility Dipl.-Ing. Werner Schönewolf Phone +49 30 39006-145 werner.schoenewolf@ipk.fraunhofer.de

Cleaning Technology Dr.-Ing. Martin Bilz Phone +49 30 39006-147 martin.bilz@ipk.­fraunhofer.de Water Systems (SysWasser) Dipl.-Ing. Gerhard Schreck Phone +49 30 39006-152 gerhard.schreck@ipk.­fraunhofer.de Traffic and Transportation Dipl.-Ing. Werner Schönewolf Phone +49 30 39006-145 werner.schoenewolf@ipk.­fraunhofer.de

Working Groups Berliner Runde (Machine Tools) Dipl.-Ing. (FH) Lukas Prasol, M. Sc. Phone +49 30 314-23568 prasol@iwf.tu-berlin.de Ceramics Machining Dipl.-Ing. Florian Heitmüller Phone +49 30 314-23624 heitmueller@iwf.tu-berlin.de Microproduction Technology Dr.-Ing. Dirk Oberschmidt Phone +49 30 39006-159 dirk.oberschmidt@ipk.­fraunhofer.de Blasting Technologies Simon Motschmann Phone +49 30 39006-269 simon.motschmann@ipk.­fraunhofer.de Tool Coatings and Cutting Materials M. Sc. Dipl.-Ing. (FH) Paul Fürstmann Phone +49 30 314-21791 paul.fuerstmann@iwf.tu-berlin.de

Advanced Training Claudia Engel Phone +49 30 39006-238 claudia.engel@ipk.fraunhofer.de PDM/PLM Dr.-Ing. Haygazun Hayka Phone +49 30 39006-221 haygazun.hayka@ipk.fraunhofer.de Process Management Dr.-Ing. Thomas Knothe Phone +49 30 39006-195 thomas.knothe@ipk.­fraunhofer.de Simulation and Factory Planning Dr.-Ing. Thomas Knothe Phone +49 30 39006-195 thomas.knothe@ipk.­fraunhofer.de Self-Organising Production (SOPRO) Dipl.-Ing. Eckhard Hohwieler Phone +49 30 39006-121 eckhard.hohwieler@ipk.­fraunhofer.de Virtual Reality Solution Center (VRSC) Elisabeth Brandenburg Phone +49 30 39006-241 elisabeth.brandenburg@ipk.fraunhofer.de Knowledge Management Dipl.-Kfm. Sven Wuscher Phone +49 30 39006-303 sven.wuscher@ipk.­fraunhofer.de Center for Innovative Product Creation (ZIP) Dr.-Ing. Haygazun Hayka Phone +49 30 39006-221 haygazun.hayka@ipk.fraunhofer.de