R&D and Applications in Automotive and Transport Industry · R&D and Applications in Automotive and...

© Fraunhofer

Nondestructive Characterization and Quality Control of Lightweight Materials and Assemblies

(Advanced Joining Technologies)

R&D and Applications in Automotive and Transport Industry

[email protected] Fon +49 9302 / 3610Fraunhofer IZFP | Campus E3 1 | 66123 Saarbrücken, Germanywww.izfp.fraunhofer.de

Prof. Dr. Bernd Valeske

AIST Tsukuba Central, Auditorium, Oct. 3rd – 5th 2017

© Fraunhofer

Tsukuba / JAPANOct 3rd – 5th 2017

[email protected] Fon +49 9302 / 3610

www.izfp.fraunhofer.de2

OUTLINE

Introduction to Fraunhofer IZFP & MissionNDE of the future: Life Cycle Monitoring & Materials Data Space

NDE for Product Development

Production-Integrated NDT for In-Situ Process Control

NDT for Quality Control of Products

Outlook

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Fraunhofer-Gesellschaft at a Glance

The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit to society.

24,000 staff

More than 70%is derived from contracts with industry and from publicly financed research projects.

Almost 30%is contributed by the German federal and Länder Governments.

67 institutes and research units Fin

an

ce v

olu

me

€2.1 billion

2016C

on

tra

ct R

ese

arc

h

€1.8 billion

Major infrastructure capital expenditure and defense research

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Fraunhofer-Gesellschaft : Applied Research

Fraunhofer Mission

New Business Models

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FRAUNHOFER IZFP …

… develops sensor & system technologies and evaluation tools to be usedfor non-destructive monitoring along the complete product life-cycle

Saarbrücken: app. 200personnel / scientific staff(app. 115 full time equiv.)EZRT Fürth: ~ 100 pers.

Budget SB ~ 16 Mio €

Industry Contracts SB ~ 7,5 Mio €

Budget Fürth ~ 14 Mio €

Location Saarbrücken

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FRAUNHOFER IZFP …

EZRT Fürth

… develops sensor & system technologies and evaluation tools to be usedfor non-destructive monitoring along the complete product life-cycle

Budget SB ~ 16 Mio €

Industry Contracts SB ~ 7,5 Mio €

Budget Fürth ~ 14 Mio €

Saarbrücken: app. 200 personnel / scientific staff(app. 115 full time equiv.)EZRT Fürth: ~ 100 pers.

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www.izfp.fraunhofer.de

FRAUNHOFER IZFPMission / future NDE

Fraunhofer IZFP uses the competences

of intelligent data acquisition based on complex, nondestructivesensor systems / sensor physics

in order to generate information (smart materials information) by means of intelligent data analytics

for the optimization of process models along the entire life cycle

with the goal of

optimum safety, efficiency and quality

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Automotive

Rail(way)

Aviation & Space

Energy

Agriculture / Bio Engineering

Infrastructure / Construction

Security

Sports/ Leisure Goods

Fraunhofer IZFPBusiness Fields / Industry Segments for Life Cyle Monitoring Applications

No airplane would be flying, no car would be driving without non-destructive monitoring!

New products need modern NDE!

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Development of system solutions for:

Characterization(raw materials | materials)

Definition of parameters(product development)

Monitoring and control(production process)

Quality control(product)

Condition monitoring(trade | operation)

Sorting of materials(recycling)

Intelligent Crosslinking

Within a single stage of PLC

Between different PLC stages

Optimizationof reliability, cost effectiveness and sustainabilityof new materials and products

FRAUNHOFER IZFPCustomized Competencies – Product Life Cycle (PLC)

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Future NDT 4.0 System Design from Data Acquisition /Sensor Physics up to Data Evaluation & Analyticswithin the Digital Product Space

Data-Transfer, Interaction & Embedded NDT Systems in Digital Environments

Digital Tools for NDEInterfaces

Source: Fraunhofer IZFP

Signal GenerationInteraction with object / material

Data Acquisition Detectors / Sensors

3D-Reconstruction

Signal- & Image Processing,Metadata, Reduction

Data / Image / Signal Analysis- automatically- local / global

SENSOR DEVELOPMENTAND DATA ACQUISITION

APPLICATION- ANDMATERIALS KNOWLEDGE

METHOD DEVELOPMENTAND DATA EVALUATION

SYSTEM DESIGN

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Scientific Competencies (core competencies)

Data acquisition – development of sensors for different nondestructivetechnologies

Data evaluation – “3D imaging“ and “3D image processing“

Application and material know-how – data analytics, smart materialsinformation

System development – subsystems, lab systems, industrial systems

Technological Competencies

Acoustics, Ultrasound

Electromagnetic Methods

Thermographic Imaging

Eddy Current

X-Ray….

Customized Competencies (Product Life Cycle)

Raw Material Analysis

Material Characterization

Process Monitoring

Quality Assurance

Condition / Operation Monitoring

Recycling / Material Sorting

FRAUNHOFER IZFPStrategic Competences

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Data Acquisition, Transport & Processinginto Smart Materials Data for Optimization

of any kind of Process ( NDE 4.0 + IoT)

Source: https://www.bitkom.org/industrie40/

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Data ScienceBusiness Intelligence

Complexity

Ass

et

/ B

en

efi

t

„diagnostic“

„forecast“

„pre-planning“

Descriptive Analytics

Predictive Analytics

Prescriptive Analytics

NDE 4.0: Digital Data Processing and Analytics Transfer into Information for Optimization & Process Design

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DB

Data base with training data sets(object + opt. parameter)

Artificial Neural Network,Deep Learning, Machine Learning

Componentcharacteristics

Optimal parameter

TrainingAlgorithm

GUI

NDE 4.0Complex Sensor Systems with Artificial Intelligence

Source: Fraunhofer EZRT / IZFP

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FRAUNHOFER IZFPCertified Systems for NDE 4.0

The Fraunhofer IZFP quality management system is certified in accordance with DIN EN ISO 9001.

The certification encompasses “the research, development, qualification and application of nondestructive testing technologies”.

Fraunhofer IZFP also operates a flexible test lab that is accredited in accordance with DIN EN ISO/IEC 17025.

The accreditation is internationally accepted under the “ILAC-MRA” agreement.

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OUTLINE





Outlook

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Source: Böllhoff / Volkswagen

Lightweight Design Multi-Material Use Innovative Joining Techniques

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Monitoring alongthe Product Life Cycle

XXL-CT Validation & Improvement of design for optimal crash performance

Fraunhofer EZRT

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Monitoring alongthe Product Life Cycle: XXL-CT

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FRAUNHOFER IZFPNondestructive Monitoring along the Product Life Cycle

Data analysis and geometric data extraction from XXL crashed CTs

Validation of crash-simulations CT for Ground Truth

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Monitoring in Production: In-Process Screw Control

Control of Correct Clamp Loadfor optimized screwing process

Smart Sgnal Conduction UltrasoundTransducer

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Monitoring in Production: In-Process (real-time control)

RIVTAC-Technology Process Monitoring withAirborne and Structure Borne Ultrasound

PositioningEntering

Penetration

Bracing

US Transducer

Jointing Points

Sensor forStructure BorneSound

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incompletepenetration/bracing„free track“

O.K.

punchingthrough

Signal Amplidute (y) as a function of process time (x) for RIVTAC

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Monitoring in Production: In-Situ Control of Welding Process

Laser Welding Welding penetration with acoustic emission Welding defects with acoustic emission Hardness and residual stress with 3MA Process monitoring and control Process optimization with power ultrasound

Friction Stir Welding, FSW Inline testing (e.g. with EMAT, thermography) Process monitoring (e.g. acoustic emission) Process control (e.g. MonStir®) Process optimization with power ultrasound

(UltraSound Enhanced – USE FSW)

Resistance Spot Welding Hardness and residual stress with 3MA Nugget size with 3MA and ultrasound Process monitoring and control Process optimization with power ultrasound

SLM (Selective Laser Melting) Process monitoring with acoustic emission

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Process Control Loop (Real-Time Control)using In-Situ Airborne Ultrasound

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Friction Stir Welding of Aluminium

homogeneous mixing

no pores, no cracks

inhomogeneous mixing

pores & cracks

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Monitoring in Production: In-Process Control of Spot Welding

Spot WeldingSpot Welding Tool

with integrated ndt controlPhysical Principle

(Ultrasound Transducer)

electrodetransversalwave

electrode

weldingspot

part 1

part 2

transmitter

receiver

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Chassis: Lamborghini Huracán

Robot based CT, Corresponding Robots carry source and detector

CT of A-pillar of the car during production

No chance to inspect by standardComputedTomography

Monitoring along the ProductLife Cycle: Welding & Bonding

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Body Parts:B-pillar

floor panelside intrusion beam

Crash zones

Body and Frame Requirements: Yield Strength, Hardness, Toughness ….

Production Monitoring and ControlUltra-Highstrength Steels (Presshardening)

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Complex Production Chain (Presshardening)

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MicromagneticInspection Device (3MA)

Nondestructive Measurement• Hardness• Yield strength, Rp0.2• Ultimate tensile strength, Rm• Elongation, A50

Collaborative Robotics


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Monitoring alongthe Product Life Cycle

Novel X-ray technology DRAGONFLY is reducing the analysis time by 50%

Automated Inspection of lightweight aluminium castings

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Automated Inspectionof Polymer Composite Products

Battery Crashbox (e-car)

Metal Mesh

FotoThgr.

Foto

GFRP base material

Thgr.

Thgr.

complex mutlti-material bodywith GFRP base material

Structure CFRP Layer

Structure Metal Mesh

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Battery Crashbox (e-car)

Thermography: Pulse-Phase-Analysis @ 0,05 Hz

6 mm

5 mm

4 mm

3 mm

2 mm

Reference defects in 2 mm depth

Delaminationat metal inlay(mount support)

Video

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Air-Coupled Ultrasoundfor automated inspectionofBattery Crashbox (e-car)

Defects Microstructure

465 kHz 260 kHz


customized transducers(IZFP patent)

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Sampling-Phased Array Ultrasound (TF, FMC)of CFRP Wheel (3D Inspection)

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C-Scan (Projection)

Sampling-Phased Array Ultrasound (TF, FMC)of CFRP Wheel (3D Visualization)

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OUTLINE





Outlook

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FRAUNHOFER IZFP: Optimized Product Lifecycle-Management

OptimizedProducts

byCrosslinkingthe (Digital) Information

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Fraunhofer IZFP

FRAUNHOFER IZFPFrom NDT Data to Materials & Process Information

CognitiveSensor SystemsNondestructivematerials analysis

Material neardata acquisition

Sensor neardata evaluation

S m a r t M a t e r i a l s I n f o r m a t i o n

Data Analytics Process Control

Data

(Smart Materials

Information)

Reaction (PLC)

Information

(I4.0, Big Data)

Production, logistics, cost, processingdata

External

NDE 4.0

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Acknowledgements

To all my colleagues at Fraunhofer IZFP for contributions inR&D works and in the recent projects

Especially:Dr. Bernd Wolter (Head of Division Process Integrated Testing)Dr. Benjamin Strass (Friction Stir Welding)Dr. Thomas Waschkies (Air Coupled Ultrasound, Acoustics)Dr. Udo Netzelmann (Thermography)Christian Conrad (3MA applications press-hardened steels)Dr. Felix Porsch (Xray CT)Prof. Dr. Ute Rabe (Phased Array Ultrasound)Prof. Dr. Ahmad Osman (Advanced Data Processing And Pattern Recognition)…. and many more

© Fraunhofer




Non-Destructive Monitoring in the Product Life Cycle

by Smart Sensors and NDE 4.0

Prof. Dr. Bernd [email protected] Fon +49 9302 / 3610Fraunhofer IZFP | Campus E3 1 | 66123 Saarbrücken, Germanywww.izfp.fraunhofer.de

R&D and Applications in Automotive and Transport Industry · R&D and Applications in Automotive and...

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