One of the hot topics currently in manufacturing domain is direct digital manufacturing. With introduction of cheap three-dimensional printers, the direct digital manufacturing seems to become a new ...manufacturing paradigm with an entirely different impact on society; nevertheless how this will impact the society and the differences between the paradigms are unclear. According to this background, this paper presents a comprehensive analysis of direct digital manufacturing from different perspectives in comparison to various traditional manufacturing paradigms. Authors are using a societal viewpoint to see, describe and analyse the subject instead of traditional manufacturing viewpoint. For the better understanding of direct digital manufacturing origins, a classification and historical background about available techniques are described. Furthermore, direct digital manufacturing as a paradigm is analysed and compared with craft production, mass production and mass customisation. Direct digital manufacturing's sustainability aspects related to social, economical and environmental dimensions are gathered and analysed for a better insight of this technique. A detailed case study demonstrates the energy use differences of direct digital manufacturing and mass production in depth. According to the present work, direct digital manufacturing has the possibility of combining the advantages of the other production paradigms and can have a positive impact on sustainable development; yet, there are several challenges to overcome both in technical and sociality aspects. A challenge within the social aspects can be the life style changes which can impact the job market, working environment, waste management and more.
•An overview of direct digital manufacturing is presented from different perspectives.•Direct digital manufacturing paradigm as an evolution of traditional manufacturing.•Direct digital manufacturing discussed and analysed under sustainability prism.•Energy consumption comparison for manufacturing using SLS and injection moulding.
Sustainability in manufacturing and factories of the future Herrmann, Christoph; Schmidt, Christopher; Kurle, Denis ...
International journal of precision engineering and manufacturing-green technology,
10/2014, Volume:
1, Issue:
4
Journal Article
Modelling and analysing lifecycle environmental impacts of product systems demands often specialized knowledge and is time-demanding. Product systems are typically defined by complex technical ...foreground systems and immersed in highly diverse contexts and background systems. Available software tools fail to streamline the modelling and analysis of this complexity, leading to extensive iterations or rough simplifications. The approach introduced in this paper supports the modelling of complex systems and their interactions with diverse backgrounds. This enables developing flexible and comprehensive environmental assessment tools. The applicability and advantages of the approach developed is demonstrated through its application for the environmental assessment of electric vehicles.
Battery production has become an increasingly important issue for industry e.g. due to the advent of electric cars and the greening of grids. The battery production chain is very interdisciplinary ...and consists of many specialised, innovative processes and numerous influencing factors. In contrast to more established sectors, processes and their interactions are not well understood yet. Thus, this paper presents a data mining approach for predicting different quality parameters of battery cells based on extensive data acquisition over the whole process chain. The results can be used to improve the planning and control of battery production.
Sustainability in manufacturing and factories of the future Herrmann, Christoph; Schmidt, Christopher; Kurle, Denis ...
International journal of precision engineering and manufacturing-green technology,
10/2014, Volume:
1, Issue:
4
Journal Article
An increasing global demand for natural resources and the inherent challenges accompanying this demand pose a great task for manufacturing companies. Apart from this, new technologies and a ...demographic change of the workforce as well as the desire for new individualized products make manufacturing more challenging than ever. To succeed in this new setting manifold perspectives of a factory have been proposed in order to enhance the understanding of the complex interdependencies between the factory elements. Against this background, this paper starts with a short overview regarding the paradigm change in manufacturing including contemporary trends triggering the requirements for factories of the future. Subsequent to that, a selection of factory perspectives is revised indicating the demand for a new holistic perspective of a factory that is more suitable with respect to the new trends. For that reason a new holistic perspective on the factory of the future is presented.
Due to the significant ecological relevance and constantly rising prices, energy consumption more and more gets into the focus of manufacturing companies which strive to consciously consider energy ...consumption when planning and managing production facilities. Thereby it is important to take into account the interdependencies of all technical processes (production and technical building services). Against this background this paper presents an integrated concept to foster energy efficiency in manufacturing companies on different layers. Important part of the concept is an appropriate simulation approach. The approach enables to derive and evaluate technical as well as organizational measures to increase energy efficiency with respect to both ecological and economic objectives.
Cyber-physical production systems (CPPS) and digital twins (DT) with a data-driven core enable retrospective analyses of acquired data to achieve a pervasive system understanding and can further ...support prospective operational management in production systems. Cost pressure and environmental compliances sensitize facility operators for energy and resource efficiency within the whole life cycle while achieving reliability requirements. In manufacturing systems, technical building services (TBS) such as cooling towers (CT) are drivers of resource demands while they fulfil a vital mission to keep the production running. Data-driven approaches, such as data mining (DM), help to support operators in their daily business. Within this paper the development of a data-driven DT for TBS operation is presented and applied on an industrial CT case study located in Germany. It aims to improve system understanding and performance prediction as essentials for a successful operational management. The approach comprises seven consecutive steps in a broadly applicable workflow based on the CRISP-DM paradigm. Step by step, the workflow is explained including a tailored data pre-processing, transformation and aggregation as well as feature selection procedure. The graphical presentation of interim results in portfolio diagrams, heat maps and Sankey diagrams amongst others to enhance the intuitive understanding of the procedure. The comparative evaluation of selected DM algorithms confirms a high prediction accuracy for cooling capacity (R2 = 0.96) by using polynomial regression and electric power demand (R2 = 0.99) by linear regression. The results are evaluated graphically and the transfer into industrial practice is discussed conclusively.
To meet the sustainable development goals of the United Nations, the energy and resource efficiency of industrial processes have to increase, and workplaces have to become decent for the involved ...workers. Plating process chains are typically associated with high energy and resource demand and the use of hazardous chemicals. For the analysis and improvement of the energy and resource efficiency as well as for modelling the occupational safety and health risks, a variety of separate approaches are available. Combined approaches are not available yet. An agent-based simulation is used as the basis for integrated energy and resource as well as occupational safety and health risk assessment. In particular, an energy and resource flow model provides the life cycle inventory data for an environmental assessment. The integration of a mechanistic inhalation exposure model through a surrogate model approach enables a combined synergetic consideration of environmental and occupational safety and health effects. A simulation case study shows the impact of chrome acid changes in chrome electroplating processes as well as the effect of different rinsing cascade settings and rinsing control strategies.
The design and development of composite structures requires precise and robust manufacturing processes. Composite materials such as fiber reinforced thermoplastics (FRTP) provide a good balance ...between manufacturing time, mechanical performance and weight. In this contribution, we investigate the process combination of thermoforming FRTP sheets (organo sheets) and injection overmolding of short FRTP for automotive structures. The limiting factor in those structures is the bond strength between the organo sheet and the overmolded thermoplastic. Within this process chain, even small deviations of the process settings (e.g., temperature) can lead to significant defects in the structure. A cyber physical production system based framework for a digital twin combining simulation and machine learning is presented. Based on parametric Finite-Element-Method (FEM) studies, training data for machine learning methods are generated and a FEM surrogate is developed. A comparison of different data-driven methods yields information on the estimation accuracy of task-specific data-driven methods. Finally, in accordance with experimental cross tension tests, the investigated FEM surrogate model is able to predict the interface bond strength quality in dependence of the process settings. The visualization into different quality domains qualifies the presented approach as decision support.
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