Advances in Automotive Production Technology – Towards Software-Defined Manufacturing and Resilient Supply Chains: Stuttgart Conference on Automotive Production (SCAP2022)

Editorial
Contents
Part A: Software-Defined Manufacturing
Real-Time Capable Architecture for Software-Defined Manufacturing
	1 Introduction
		1.1 Limitations of State of the Art Manufacturing Systems
		1.2 Software-Defined Manufacturing as a New Paradigm
	2 Requirements Analysis Based on Related Work
		2.1 Requirements from the Automation Application Life Cycle
		2.2 Requirements Based on Published Approaches to SDM
	3 Architecture Proposal
		3.1 Integration in a Conceptual SDM Framework
		3.2 Virtualization and Orchestration
		3.3 Network and Application Configuration
	4 Conclusion and Future Work
	References
Analysis of Real-Time Execution Models for Container-Based Control Applications
	1 Introduction
	2 Related Work
	3 Analysis of Scheduling Methods
	4 Execution Models for the Container-Based PLC
		4.1 Cyclic Execution Model
		4.2 Event-Based Execution Model
	5 Validation of a Sample Use-Case
	6 Conclusion and Future Work
	References
Software-Defined Manufacturing for the Entire Life Cycle at Different Levels of Production
	1 Introduction
	2 State of the Art
	3 Approach
		3.1 Machine
		3.2 Production System
		3.3 Production Network
	4 Exemplary Use Case
	5 Discussion and Conclusion
	References
Dynamic Safety Distance Determination for Human Robot Coexistence in Industrial Applications*-12pt
	1 Introduction
	2 Related Work
	3 Accurate Speed and Separation Monitoring
		3.1 Calculation According to the Norm
		3.2 Human and Robot Modeling
		3.3 Implementation Details and Monitoring Differences
	4 Simulation
		4.1 Scenario
		4.2 Implementation Details
		4.3 Evaluation
	5 Requirements and Safety Discussion
	6 Conclusion and Future Prospects
	References
Integrated Framework for Safety Management and Software-Assisted Safety Assessment in Fluid Production*-12pt
	1 Introduction
	2 Related Work
	3 Modeling and Integrated Process for the System Commissioning
	4 Fluid Production Safety 4A-Framework (FluPro-S4A)
		4.1 Step 1: Change Acknowledgement
		4.2 Step 2: Asset Assessment
		4.3 Step 3: System Assessment
		4.4 Step 4: Approval Assistance
	5 Case Study
	6 Conclusion and Future Work
	References
Part B: Data-Driven Technologies
Improvement of the Scheduling of Automotive Testing Processes Based on Production Scheduling Methods
	1 Introduction
	2 State of the Art
	3 Test Field Modelling
		3.1 Physical Test Field
		3.2 Virtual Test Field
	4 Scheduling Results
	5 Conclusion and Outlook
	References
Mixed-Integer Programming Model for Scheduling of Modular Automotive Body-In-White Production Systems*-12pt
	1 Introduction
	2 State of the Art
	3 Proposed Mixed-Integer Programming Model
		3.1 Notations
		3.2 Model
	4 Results and Discussion
	5 Conclusion
	References
Robotic Assembly Line Balancing with Multimodal Stochastic Processing Times*-12pt
	1 Introduction
	2 State of Research
	3 Objective
	4 Genetic Algorithm
		4.1 Solution Representation
		4.2 Steps of the GA
		4.3 Decoding Procedure for the RALBP
	5 Results
	6 Conclusion and Future Research
	References
Elementary Welding Operations for Automatic Robot Programming
	1 Introduction
	2 Related Work
	3 Elementary Welding Operation
	4 Technical Implementation
	5 Experiments and Results
	6 Discussion and Conclusion
	References
Influence of the Joining Force on the Nugget Diameter During Resistance Spot Welding of Aluminum Materials
	1 Introduction
	2 Hypothesis and Method
	3 Literature Review
	4 Setup
		4.1 Material
		4.2 Equipment and Execution
		4.3 Meta Data and Design of Experiments
	5 Target Data and Feature Engineering
		5.1 Target Data
		5.2 Feature Engineering
	6 Results
		6.1 Machine Learning Approaches
		6.2 Permutation Feature Importance
		6.3 Visualization of Datasets
		6.4 Second Degree Regression
	7 Conclusion and Outlook
	References
Towards an Automated System for Robot Assembly Cell Layout Optimization
	1 Introduction
	2 Aspects of Automated Layout Optimization
		2.1 Definition of Criteria for 3D Simulation Generation and Optimization
	3 Approaches for 3D Modelling and Optimization
	4 State of the Art Discussion
	5 Concept Formulation
	6 Conclusion and Next Steps
	References
Adaptive Intralogistics with Low-Cost AGVs for a Modular Production System*-12pt
	1 Introduction
	2 Current Situation
	3 Novel Platform for Modular Production
	4 Scalable Low-Cost AGV Construction Kit
	5 Communication Using Dynamic LED Tracks
	6 Conclusion
	References
Topology Planning in Swarm Production System: Framework and Optimization
	1 Introduction
	2 State of the Art
		2.1 FLP in Changeable Manufacturing
		2.2 Optimization Methods in FLP
		2.3 Optimization with Graph Theory
		2.4 Optimal Approach in Topology Manager(TM)
	3 Topology Manager Framework
	4 Exemplification
		4.1 Batch Processing Module
		4.2 Topology Estimation and Optimization Module
		4.3 Reconfiguration Decision Module
	5 Experimental Results
	6 Discussion and Conclusion
	References
Using Meta-Learning to Reduce the Effort of Training New Workpiece Geometries for Entanglement Detection in Bin-Picking Applications*-12pt
	1 Introduction
	2 Meta-Learning
	3 Meta-Learning Applied to the Entanglement Detection
		3.1 Base Dataset
		3.2 Implementation to the Entanglement Detection
		3.3 Training of the Meta-Learning Methods
	4 Results
		4.1 Comparison of Applied Meta-Learning Methods
		4.2 Performance Validation of the Meta-trained Entanglement Detection on Unseen Workpiece Geometries
	5 Summary and Outlook
	References
Performance Comparison of Supervised and Reinforcement Learning Approaches for Separating Entanglements in a Bin-Picking Application*-12pt
	1 Introduction
	2 State of the Art
	3 New Supervised Learning Entanglement Separation Method
		3.1 Data Generation
		3.2 Network Architecture
		3.3 Training
		3.4 Threshold Evaluation
	4 Comparison
		4.1 Setup Effort
		4.2 Real-World Performance Comparison
		4.3 Integration into a Bin Picking System
	5 Conclusion and Future Work
	References
Machine Learning-Based Identification of Root Causes for Defective Units in Manufacturing Processes
	1 Introduction
	2 Theoretical Background
		2.1 Classical Methods
		2.2 Method Based on Attention Mechanism
	3 Data
	4 Results
	5 Discussion
	6 Conclusion
	References
Enabling Single-Sensor Simultaneous Condition Monitoring of Several Vibration-Emitting Machine Parts Using Neural Networks
	1 Introduction
	2 Theoretical Background and Methods
		2.1 Convolutional Neural Network
		2.2 Discrete Fourier Transform
		2.3 Methods
	3 Experimental Setup
	4 Results
		4.1 Data Transformation
		4.2 Training and Evaluation
		4.3 Discussion
	5 Conclusion
	References
Unlocking the Potential of Digital Twins
	1 Introduction
	2 State of the Art
		2.1 Life Cycle of Production Plants
		2.2 Digitalisation of the Planning, Realization and Operation Phases
	3 Concept, Industrial Use Case and Challenges
		3.1 Use Cases for Digital Twins
		3.2 Development of the Virtual Commissioning Model Towards a Digital Twin
		3.3 Example of an Industrial Use Case
		3.4 Challenges
	4 Conclusion and Outlook
		4.1 Conclusion
		4.2 Outlook
	References
Hybrid Digital Twins Using FMUs to Increase the Validity and Domain of Virtual Commissioning Simulations
	1 Introduction
	2 State of the Art in Virtual Commissioning Simulations with Increased Level of Detail
	3 Methods and Concept of Hybrid Digital Twins
	4 Validation Use Case Inverted Pendulum
		4.1 Modeling and Simulation Setup
		4.2 Simulation Results and Interpretation
	5 Conclusion and Outlook
	References
Towards the Smart Factory: Process Optimization in Virtual Commissioning
	1 Introduction
	2 State of the Art
		2.1 Conventional Planning
		2.2 Digital Factory and Twin
	3 Process Analysis
		3.1 Metrics
		3.2 Problem Analysis
		3.3 Problem Solutions
	4 Process Optimization
		4.1 Process Integration
		4.2 Educating and Training Employees
		4.3 Technical Changes
		4.4 Use Cases
	5 Conclusion and Outlook
	References
A New IT Architecture for the Digital Factory
	1 Introduction
		1.1 Digital Factory
		1.2 Data Model PPR – Product, Process, Resource
		1.3 Scope
		1.4 Main Requirements
		1.5 State of the Art
	2 System Design
		2.1 General Approach
		2.2 Interface Design
		2.3 Example Application
	3 Outlook
	4 Conclusion
	References
Security Analysis of a Blockchain Based Data Collection Method for Cross Company Information Sharing
	1 Introduction
	2 Related Work
		2.1 Cross Company Data Exchange
		2.2 Threat Modelling for Production
	3 Proposed Solution Architecture
	4 System Analysis
	5 Findings
		5.1 Infrastructure
		5.2 Employee
		5.3 Business
	6 Summary
	References
Part C: Advanced Manufacturing and Sustainability
Combination of the Scanning and the Polar Measuring Method for the Defect Detection in Dry Fibre Layups Using an Eddy Current Sensor
	1 Introduction
	2 Literature Review
		2.1 Carbon Composite Manufacturing
		2.2 Eddy Current Sensors
		2.3 Measuring Methods
	3 Method
		3.1 Hardware Selection
		3.2 Specimen and Experimental Plan
	4 Results and Discussion
		4.1 Fibre Orientation
		4.2 Gap Detection
		4.3 Foreign Objects
		4.4 Discussion
	5 Conclusion
	References
Detection of Gaps and Overlaps in Laser Line Triangulation Data of Dry Fibre Tape Layups Using Image Projection
	1 Introduction
		1.1 Background
		1.2 Dry Fibre Tape Placement
		1.3 Defects and Irregularities
		1.4 Laser Line Triangulation
		1.5 In-Line Implementation
	2 Literature and Methods
		2.1 Evaluation Methods in the Literature
		2.2 Research Method for the Algorithm Assessment
		2.3 Specimen, Hardware and Preprocessing
	3 Results
		3.1 Image Projection
		3.2 Adaptive and Cell-Wise Thresholding
	4 Discussion
	5 Conclusion and Outlook
	References
Parameter Study and Optimization of Forming Simulations for Tape-Based Fiber Layups
	1 Introduction
	2 State of the Art
	3 Methodology
		3.1 Initial Finite Element Model
		3.2 Parametrization Setup
		3.3 Analysis
	4 Results
	5 Discussion
	6 Conclusion and Outlook
	References
Analysis of New Concepts for the Consolidation Roller in Laser-Assisted Automated Tape Placement Processes
	1 Introduction
		1.1 Thermoplastic In-Situ AFP
		1.2 Compaction Roller Overview
	2 Methodology
		2.1 Analytical Analysis of Compaction Roller Contact and Deformation
		2.2 Compaction Rollers Fabrication and Experimental Test Setup
		2.3 Simulation Setup
	3 Results and Discussion
		3.1 Experimental Results: Pressure Uniformity
		3.2 Experimental Results: Compaction Pressure
		3.3 Simulation
	4 Conclusion
	References
Development, Implementation and Evaluation of a Prototype System for Data-Driven Optimization of a Preforming Process
	1 Introduction
		1.1 Forming of Woven Fabrics
		1.2 Sensors for Composite Structures and Manufacturing
		1.3 Strain Sensing
		1.4 Edge Computing
	2 Experimentation
		2.1 Basic Materials
		2.2 Sensor Characterization
		2.3 Strain Sensor System
		2.4 Integration into Edge Device
		2.5 Draping Process
	3 Results
	4 Conclusion
	References
Resource Efficient Manufacturing of Complex Cooling Structures
	1 Motivation
	2 State of the Art
	3 Proposed Advantages Through the Enhancing of Injection Molded Encapsulations with Additive-Built Inserts
	4 Motivation in the HEaK Project
		4.1 Design of the Insert Structure
	5 Preliminary Investigations
		5.1 Pressure Tests
		5.2 Powder Investigations
	6 Conclusion
	References
The Potential of High Speed Sintering for Small Series in the Automotive Industry
	1 Introduction
	2 Rapid Manufacturing vs. Rapid Prototyping
	3 Introduction to High Speed Sintering
	4 Research Approach
	5 Development of Design Guidelines for HSS
	6 Use of HSS for the Manufacturing of a Speaker Cover
	7 Conclusion
	8 Limitations and Further Research
	References
Asset Administration Shell for the Wiring Harness System
	1 Introduction
	2 Changing the Value Chains for Wiring Harness
		2.1 Wiring Harness in Current Value Chains
		2.2 Vision – Uniform Data Representation Along the Complete Life Cycle
		2.3 The Asset Administration Shell
		2.4 Potentials by Using Digital Twins
	3 Asset Administration Shell for the Wiring Harness (VWS4LS)
	4 Status of Development
	5 Conclusion and Further Development
	References
Case Study on Localization for Robotic Wire Harness Installation
	1 Introduction
	2 Problem Statement
	3 Related Works
	4 Contribution
	5 Concept
		5.1 Wire Harness Localization
		5.2 Component Localization
	6 Evaluation
		6.1 Experimental Setup
		6.2 Evaluation of Wire Harness Localization
		6.3 Evaluation of Component Localization
	7 Conclusion
	References
Traceability in Battery Production: Cell-Specific Marker-Free Identification of Electrode Segments
	1 Introduction
		1.1 Traceability in Lithium-ion Battery Production
		1.2 Identification Techniques
	2 Cell-Specific Identification of Electrode Segments
		2.1 Marker-Free Identification Using Surface Microstructures
		2.2 Approach for Proving Concept Implementation
	3 Conclusion and Outlook
	References
Multi-agent Interaction Structure for Enabling Subsidiary Planning and Control in Modular Production Systems
	1 Introduction
	2 State of the Art and Related Work
		2.1 Structured Information Processing in Modular Production
		2.2 Structuring Systems for Developing a Systems Design
	3 Modelling Interaction for Planning and Control in Modular Production Systems
		3.1 Top-Down Decomposition and Bottom-Up Aggregation of a Modular Production System
		3.2 Interaction Model for Cross-System and Cross-Level Information Processing
	4 Implementation of a Subsidiary Planning and Control for Enabling a Resilient Production Flow in Modular Production
		4.1 Introduction of the Use Case
		4.2 Implementation of a Model-Based System Structure
	5 Simulation Setup and Results
	6 Conclusion
	References
Resilience to Pandemics through Flexibility in Sourcing, in Order Fulfillment, and Production Capacity of the Automotive Supply Chain
	1 Introduction
	2 Resilience of Supply Chains
	3 Supply Chain Resilience of the Automotive Industry
		3.1 Procedure
		3.2 State of Art of the Automotive Supply Chain
		3.3 Sourcing and Fulfillment Capabilities of the Automotive Supply Chain
	4 Status Quo and Recommendations
	5 Conclusion
	References
Requirements for a Process to Remanufacture EV Battery Packs Down to Cell Level and Necessary Design Modifications
	1 Introduction
	2 State-of-the-Art/Literature Review
	3 Analysis of a State-of-the-Art Battery System
	4 Remanufacturing Challenges and Design Modifications
	5 Discussion of Results
	6 Summary and Conclusion
	References
Author Index