TRUMPF (Austria)

Engineering and testing of mechatronic systems is expected to be heavily impacted by Industry 4.0 and big data, which transform the classic hierarchical information model into decentralized, distributed services. However, it is not sufficient to collect and process big volumes of data in order to realize the expected benefits of Industry 4.0. Industry companies have to establish appropriate interfaces and integration strategies with their established engineering processes and the related information systems. In this paper we present our experiences and the enterprise system infrastructure we developed for test and piloting of complex mechatronic systems at a large engineering and manufacturing company. The implemented solution has become a backbone for systems engineering and is frequently used by various stakeholders. Furthermore, we describe how we extend the approach by integrating data from machinery in the field to ensure “end-to-end digital integration” that provides feedback for the construction and testing of new systems.

This paper presents the model to estimate the reliability of high power diode laser system based on failure rate of each diode. The diodes' reliability is estimated from multi-cell life test with accelerated optical power and junction temperature. The system is then considered as a k-out-of-n:G load sharing system. The hypo-exponential distribution is applied to model the system level reliability. Two solutions to hypo-exponential model are introduced to compute the reliability at expected time and two examples are presented to illustrate the model. The numerical examples verify that the scaling and squaring method is more stable than exact algorithm considering numerical instability. Estimating with the hypo-exponential model, the single emitter diode laser system shows reliability higher than 0.999 at the lifetime required by customer.

Nowadays high power lasers are mainly used for cutting of sheet metals, for welding, hardening and rapid prototyping. In the forming of sheet metals as bending or deep drawing lasers are not used. Nevertheless a few years ago a new application of high power lasers has been invented, where bending of materials that break at room temperature becomes possible by heating them along the bending edge with high power lasers thus allowing their treatment without cracks and rupture. For this purpose a large number of diode lasers are arranged in the bottom tool of a bending machine (a V-shaped die) which heat up the initially flat sheet metal during the bending process what is performed by pressing it into the die with a knife shaped upper tool where due to the laser heating the material is softened and thus cracks are avoided. For the technical realization of the new process of laser assisted die bending, modules equipped with numerous laser diodes and a total beam power of 2,5 kW are used. The light emitted by these modules enters a tool with a length of 15cm and is deflected towards the workpiece. By using ten of these modules with adjacent dies and by integrating those in a bending press a bending edge of sheet metals with a length of 1500mm can be realized. Such a bending press with laser assistance also needs energization with a power of practically 50kW, a respective water flow, a heat exchanger system and also a control for all functions of this system. Special measures have also been developed to avoid radiating of those tools that are not covered by a workpiece in the case of bending edges shorter than the full length of the bending tools whereas individual short circuiting of diode modules can be performed. Specific measures to ensure a safe operation without any harm to the operational person have been realized. Exploitation of the bending process has been carried out for titanium, where material thicknesses up to 3mm have been bent successfully.

In mechatronics engineering the execution of experiments and tests is an important activity during development of new products and maintenance of released products. Planning and execution of experiments and tests is an essential cost and time factor. To keep the development time short it is necessary to have well-managed processes in the test department and to plan, organize, source out or execute, and document tests and experiments in an efficient and effective way. This paper contains the results of a general survey identifying existing practices, used methods and tools in industry concerning testing and piloting. Seven large-scale companies situated in Upper-Austria took part in this survey. The survey concentrates on established test processes and practices, usage of publicly available test methods, and (re)use of self-developed tests methods. Furthermore, applied practices for documentation of test results, test setup data, and used software/tools for test planning, execution, documentation, and storage were investigated in the survey. The results of the survey show established practices and possible improvement areas for test departments in industrial mechatronics engineering context.