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  • 1.
    Bolmsjö, Gunnar
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för automationssystem.
    Supporting Tools for Operator in Robot Collaborative Mode2015Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 3, s. 409-416Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Making use of robot automation for customized products put high demand not only on the robot but on the efficiency, simplicity and flexibility to actually deploy and use robots in manufacturing stations and production lines in short batches and low volume production. Hence, market oriented product development and production requires more products to be developed and offered in less time than before, and produced for the market with more customizable options. The role of the operator is in this context an important factor and tools are needed to support the operator for highly efficient and flexible production. In this paper, the development and study of supporting tools for operators is presented. A demonstrator has been built for robotic nailing, screwing and manipulation operation in producing scaled down gable wall elements in wood for a family house. Issues raised to support the operator included automatic programming and generating relevant information for the operator for the deployment procedure to prepare for production. During production, different concepts of safety system to support collaboration mode between the operator and the robot was developed and studied. Wearable devices was used for the operator to access the information generated and different safety configurations were developed and evaluated. The baseline for this work has been to identify industrial use cases which has a clear need for automation as well as collaboration between operator(s) and robot(s). Work scenarios were discussed and analyzed with industrial partners and it was concluded that, in addition to the deployment tools, a smart safety system which is able to detect and react on humans entering the robot system work area is needed. This should support for efficient production and less downtime for both automatic mode and collaboration mode. The benefit of operator – robot collaboration is clearly shown as well as the need for supporting tools.

  • 2.
    Bonilla Hernández, Ana Esther
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW). GKN Aerospace Engine Systems AB, Flygmotorvagen 1, Trollhattan, 46138, Sweden.
    On how the selection of materials affects sustainability2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 33, s. 625-631Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    The selection of the materials for the production of aerospace engine products is directly related to their performance in tough working conditions. However, the extraction of the materials requires high amounts of energy, use water and emit CO2, which can be directly related with environmental sustainability. The abundance of the materials and their sourcing and geographical location can be further related to economic and social sustainability. Manufacturing companies look for different materials and cutting data that will optimize material removal rate, cutting tool utilization, required cutting time, costs, energy used, CO2 footprint, coolants, etc. Here is presented a simple methodology to calculate the sustainability impact of the selection of materials. The study compares a simplified theoretical work piece that is geometrically complex and made of difficult to machine material, e.g. Ti-6Al-4V and MP159. The study shows how to select the optimal material, not only in terms of costs, but also in terms of environmental, societal and economical sustainability. © 2019 The Authors. Published by Elsevier B.V.

  • 3.
    Bonilla Hernández, Ana Esther
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW). GKN Aerospace Engine Systems AB, Flygmotorvagen 1, Trollhattan, 46138, Sweden.
    Lu, Tao
    University of Kentucky, Institute for Sustainable Manufacturing (ISM), Lexington, KY 40506, United States.
    Beno, Tomas
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Fredriksson, Claes
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Jawahir, I. S.
    University of Kentucky, Institute for Sustainable Manufacturing (ISM), Lexington, KY 40506, United States.
    Process sustainability evaluation for manufacturing of a component with the 6R application2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 33, s. 546-553Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Sustainability in manufacturing can be evaluated at product, process and system levels. The 6R methodology for sustainability enhancement in manufacturing processes includes: reduced use of materials, energy, water and other resources; reusing of products/components; recovery and recycling of materials/components; remanufacturing of products; and redesigning of products to utilize recovered materials/resources. Although manufacturing processes can be evaluated by their productivity, quality and cost, process sustainability assessment makes it a complete evaluation. This paper presents a 6R-based evaluation method for sustainable manufacturing in terms of specific metrics within six major metrics clusters: environmental impact, energy consumption, waste management, cost, resource utilization and society/personnel health/operational safety. Manufacturing processes such as casting, welding, turning, milling, drilling, grinding, etc., can be evaluated using this methodology. A case study for machining processes is presented as an example based on the proposed metrics. © 2019 The Authors. Published by Elsevier B.V.

  • 4.
    Edberg, Jonas
    et al.
    Luleå University of Technology, 971 87 Luleå, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Use of Indicators for Hot and Warm Cracking in Welded Structures2017Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 7, s. 145-150Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Weight reduction of mechanical components is becoming increasingly important as a way to provide more environment friendly production and operation of different equipment. This is true in almost any manufacturing industry, but is especially important to the aerospace industry. Casting has often been replaced by hot and cold metal working operations and welding, usually including an additional heat treatment. This gives components better material properties and provides components with less weight and cost but with increased strength and efficiency. This may even be true for rotating Ni- based superalloy components, and is enabled by welding methods. However, weld cracking of precipitation hardening Ni-based superalloys is a serious problem, both in manufacturing and overhaul since it endangers component life if cracks are allowed to propagate. Cracks can appear in a weld and in it’s surroundings. The triggering mechanisms depend on its location and when it is nucleated. Generally saying, weld cracking in precipitation hardening Ni-based superalloys consists of two different types of cracking, hot cracking and warm cracking which may be further divided into heat affected zone (HAZ) liquation cracking, solidification cracking and strain age cracking, respectively. Finite element simulations of welding and heat treatment processes started in the seventies for small laboratory set-up cases and have today matured, and are now used on large-scale structures like aerospace components. But FE-based crack criteria that can predict the risk of cracking due to welding or heat treatments are rare. In a recent study both hot cracking and warm cracking have been investigated in Ni-based superalloys, and two FE-based indicators showing the risk of hot and warm cracks have been proposed. The objective of the investigation presented in this paper is to compare results from FE-simulations with experimental results from weldability tests, like the Varestraint test and the high temperature mechanical Gleeble test. © 2016

  • 5.
    Fredriksson, Claes
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Sustainability of metal powder additive manufacturing2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 33, s. 139-144Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Additive manufacturing, or 3D-printing, has attracted attention and raised expectations regarding future production and repair of parts, for example, in the aerospace industry. Various techniques have been utilized to deposit metal alloys for components. It has been suggested that this may offer great benefits in terms of sustainability, in particular, new opportunities for lightweighting. There are, however, outstanding questions about sustainability benefits outside of the use phase. In this paper, the material and manufacturing life-cycle stages were investigated for details produced using INCONEL 718. Energy measurements from an ARCAM A2X Electron Beam Melting system are presented and compared to the embodied energy and indirect CO2-emissions of the feedstock as well as to traditional subtractive manufacturing. It is found that both the metal powder production and the additive manufacturing process itself contribute considerably to total energy use and emissions. Ashby’s 5-step method for assessment of sustainable development is used to briefly discuss economic and social implications of additive manufacturing. © 2019 The Authors. Published by Elsevier B.V.

  • 6.
    Hanning, Fabian
    et al.
    Chalmers University of Technology,Department of Industrial and Materials Science, S-Gothenburg, 41296, Sweden.
    Hurtig, Kjell
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Measurement of the thermal cycle in the base metal heat affected zone of cast ATI ® 718Plus TM during manual multi-pass TIG welding2018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, s. 443-449Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    This paper presents a method to acquire thermal data in the base metal heat affected zone (HAZ) during manual multi-pass TIG welding of ATI ® 718Plus TM , representing conditions close to an actual repair welding operation. Thermocouples were mounted in different locations along side walls of linear grooves to record temperature data. The thermal cycling was found to be largely independent of location within the HAZ. The recorded temperatures were below the incipient laves melting temperature, indicating that the current test setup requires optimisation to study HAZ liquation. Based on the results of this study, a modified thermocouple mounting technique is proposed. © 2018 Elsevier B.V. All rights reserved.

  • 7.
    Johansson, Pierre E. C.
    et al.
    Volvo Group Trucks Operations, Gothenburg 405 08, Sweden.
    Enofe, Martin O.
    Volvo Group Trucks Operations, Gothenburg 405 08, Sweden.
    Schwarzkopf, Moritz
    Volvo Group Trucks Operations, Gothenburg 405 08, Sweden.
    Malmsköld, Lennart
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Fast-Berglund, Åsa
    Chalmers University of Technology, Gothenburg 412 96, Sweden.
    Moestam, Lena
    Data and Information Handling in Assembly Information Systems: A Current State Analysis2017Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 11, s. 2099-2106Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Products become more complex as the general technology development reaches new levels. These new technologies enable manufacturing companies to offer better products with new functionalities to their customers. Complex products require adequate manufacturing systems to cope with changing product requirements. In general, manufacturing of this type of products entails complex structured and rigid IT systems. Due to the system’s complexity and comprehensive structure, it becomes challenging to optimize the information flow. There are improvement potentials in how such systems could be better structured to meet the demands in complex manufacturing situations. This is particularly true for the vehicle manufacturing industry where growth in many cases have occurred through acquisitions, resulting in increased levels of legacy IT systems. Additionally, this industry is characterized by high levels of product variety which contribute to the complexity of the manufacturing processes. In manual assembly of these products, operations are dependent on high quality assembly work instructions to cope with the complex assembly situations. This paper presents a current state analysis of data and information handling in assembly information systems at multiple production sites at a case company manufacturing heavy vehicles. On basis of a certain set of characterizing manual assembly tasks for truck, engine and transmission assembly, this work focuses on identifying what data and information that is made available to operators in terms of assembly work instructions and the importance of such data and information. This work aims to identify gaps in the information flow between manufacturing engineering and shop floor operations. © 2017 The Authors

  • 8.
    Johansson, Pierre E.C.
    et al.
    Volvo Group Trucks Operations, Gothenburg, 405 08, Sweden; Chalmers University of Technology, Gothenburg, 412 96, Sweden.
    Malmsköld, Lennart
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Fast-Berglund, Åsa
    Chalmers University of Technology, Gothenburg, 412 96, Sweden.
    Moestam, Lena
    Volvo Group Trucks Operations, Gothenburg, 405 08, Sweden.
    Enhancing Future Assembly Information Systems: Putting Theory into Practice2018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 17, s. 491-498Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    The manufacturing industry is in a changing state where technology advancements change the mindset of how manufacturing systems will function in the future. Industry 4.0 provides manufacturing companies with new methods for improved decision-making processes and dynamic process control. Despite this ambition, the manufacturing industry is far away from implementing this approach in practice. Assembly information systems will play an even more vital role enabling information transfer from product design to shop floor assembly in the future. To prepare the industry for these changes that are foreseen and for those that are yet to be discovered, a learning factory environment is vital. Such an environment is intended to support the industry during the development of assembly information systems. This paper presents an industrial demonstrator which incorporates well-known methods for improving assembly work stations with the perspective on assembly information systems. These methods are still not widely used in manual assembly intense manufacturing companies. This demonstrator illustrates how established theories can be practically used when designing future assembly information systems. The demonstrator will be used to validate functionalities and requirements for future assembly information systems.

  • 9.
    Kisielewicz, Agnieszka
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Sikström, Fredrik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Christiansson, Anna-Karin
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Ancona, Antonio
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Spectroscopic monitoring of laser blown powder directed energy deposition of Alloy 7182018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, s. 418-425Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Experimental explorations of a spectrometer system used for in-process monitoring of the laser blown powder directed energy deposition of Alloy 718 is presented. Additive manufacturing of metals using this laser process experiences repeated heating and cooling cycles which will influence the final microstructure and chemical composition at every given point in the built. The spectrometer system disclosed, under certain process conditions, spectral lines that indicate vaporisation of chromium. Post process scanning electron microscope energy dispersive spectroscopy analysis of the deposited beads confirmed a reduction of chromium. Since the chromium concentration in Alloy 718 is correlated to corrosion resistance, this result encourages to further investigations including corrosion tests.

  • 10.
    Mi, Yongcui
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Sikström, Fredrik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Nilsen, Morgan
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Ancona, Antonio
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS). CNR-IFN Institute for Photonics and Nanotechnologies, Physics Department, via Amendola 173, Bari, 70126, Italy.
    Vision based beam offset detection in laser stake welding of T-joints using a neural network2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 36, s. 42-49Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    This paper presents an experimental study where a vision camera integrates coaxially into a laser beam welding tool to monitor beam deviations (beam offset) in laser stake welding of T-joints. The aim is to obtain an early detection of deviations from the joint centreline in this type of welding where the joint is not visible from the top side. A polynomial surface fitting method is applied to extract features that can describe the behaviour of the melt pool. A nonlinear autoregressive with exogenous inputs neural network model is trained to relate eight image features to the laser beam offset. The performance of the presented model is evaluated offline by different welding samples. The results show that the proposed method can be used to guide post weld inspection and has the potential for on-line adaptive control. © 2019 The Author(s). Published by Elsevier B.V.

  • 11.
    Nilsen, Morgan
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Sikström, Fredrik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Christiansson, Anna-Karin
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    A study on change point detection methods applied to beam offset detection in laser welding2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 6, s. 72-79Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    This paper presents an experimental study where a photodiode integrated into a laser beam welding tool is used to monitor laser beam spot deviations fromthe joint, the beam offset. The photodiode system is cost effective and typically easy to implement in an industrial system. The selected photodiode is a silicondetector sensitive in the spectral range between 340-600nm which corresponds to the spectral emissions from the plasma plume. The welding application is closed-square-butt joint welding where a laser beam offset can cause lack of fusion in the resulting weld. The photodiode signal has been evaluated by two different change point detection methods, one off-line and one on-line method, with respect to their detection performance. Off-line methods can be used to guide post weld inspection and on-line methods have the potential to enable on-line adaptive control or the possibility to stop the process for repair. The performance of the monitoring system and the change point detection methods have been evaluated from data obtained during laser beam welding experiments conducted on plates of stainless steel. The results clearly indicates the possibility to detect beam offsets by photodiode monitoring.

  • 12.
    Nilsen, Morgan
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Sikström, Fredrik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Christiansson, Anna-Karin
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Ancona, Antonio
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    In-process Monitoring and Control of Robotized Laser Beam Welding of Closed Square Butt Joints2018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, s. 511-516Artikkel i tidsskrift (Annet vitenskapelig)
    Abstract [en]

    In robotized laser welding of technical zero gap closed square butt joints it is critical to position the laser beam correct with regardsto the joint. Welding with an offset from the joint may cause lack of sidewall fusion, a serious defect that is hard to detect and gives a weak weld . When using machined parts with gap and misalignment between the parts that is close to zero, existing joint tracking systems will probably fail to track the joint. A camera based system using LED illumination and matching optical filters is proposed in this paper to address this issue. A high dynamic range CMOS camera and the LED illumination is integrated into the laser tool. The camera captures images of the area in front of the melt pool where the joint is visible and an algorithm based on the Hough transform and a Kalman filter estimates the offset between the laser spot and the joint position. Welding experiments, using a 6 kW fiber laser, have been conducted to evaluate the performance of the system. Promising results are obtained that can be used in the further development of a closed loop controlled joint tracking system.

  • 13.
    Raza, Tahira
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Svensson, Lars-Erik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Microstructure of Selective Laser Melted Alloy 718 in As-Manufactured and Post Heat Treated Condition2018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, s. 450-458Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Manufacturing of Alloy 718 with selective laser melting (SLM) process faces several challenges. One of the challenges is the process-induced porosities in as-manufactured SLM parts. Another challenge is the microstructure of Alloy 718 that contains a high amount of segregating elements, such as MC-type carbides and γ/Laves phase eutectics in interdendritic regions. The microstructural heterogeneity in the as-manufactured SLM part unavoidably leads to mechanical heterogeneity and hence, post-processing heat treatments become necessary to achieve a homogeneous microstructure. Therefore, by investigating various post heat treatment options the knowledge on how to decrease/eliminate these segregations will be developed. © 2018 Elsevier B.V. All rights reserved.

  • 14.
    Sikström, Fredrik
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Nilsen, Morgan
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för produktionssystem (PS).
    Beam offset detection in laser stake welding of tee joints based on photodetector sensing2019Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 36, s. 64-71Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    This paper presents an experimental study where a photodetector is used in a laser beam welding tool to monitor beam deviations (beam offsets) in stake welding of tee joints. The aim is to obtain an early detection of deviations from the joint centerline in this type of welding where the joint is not visible from the top side. The photodetector used is a GaP diode sensitive in the spectral range 150-550 nm corresponding to the spectral emissions form the plasma plume during keyhole welding. The photodetector signal has been evaluated by change point detection methods with respect to their detection performance. Both an off-line and an on-line method have been evaluated. The off-line method can be used to guide post weld inspection and the on-line method has the potential to enable on-line adaptive position control and/or the possibility to stop the process for repair. The results shows that the proposed method can be used as a go/no go system and to guide post weld inspection.

  • 15.
    Singh, Sukhdeep
    et al.
    Department of Industrial and Materials Science, Chalmers University of Technology, Gothenburg, Sweden.
    Hurtig, Kjell
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Investigation on effect of welding parameters on solidification cracking of austenitic stainless steel 3142018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, s. 351-357Artikkel i tidsskrift (Annet vitenskapelig)
    Abstract [en]

    This study investigates the solidification cracking susceptibility of the austenitic stainless steel 314. Longitudinal Varestraint testing was used with three different set of welding test parameters. Weld speed, current and voltage values were selected so that the same heat input resulted in all the test conditions. From the crack measurements it was seen that the test condition with the lowest current and welding speed value also produced the least amount of cracking with very good repeatability.

  • 16.
    Svenman, Edvard
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW). GKN Aerospace Engine Systems, Trollhättan, Sweden.
    Modeling of inductive coil geometry for gap position measurement2018Inngår i: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, s. 103-110Artikkel i tidsskrift (Annet vitenskapelig)
    Abstract [en]

    Finite element modelling of high frequency inductive coils and metal plates was used to investigate the impedance response to a narrow gap between the plates. The model was used to predict distance sensitivity for both coil-to-gap and coil-to-plate. Different coil axis orientations, along and across the gap and normal to the plate, were modeled, as well as different coil lengths. The model can be used to predict the working range and select orientation and geometry of inductive seam tracking probes with zero gap capability for precision laser beam welding. Different materials, thicknesses and frequencies can be used.

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