The paper deals with the modeling and fault-tolerant control of a real battery assembly system which is under implementation at the RAFI GmbH company (one of the leading electronic manufacturing service providers in Germany). To model and control the battery assembly system, a unified max-plus algebra and model predictive control framework is introduced. Subsequently, the control strategy is enhanced with fault-tolerance features that increase the overall performance of the production system being considered. In particular, it enables tolerating (up to some degree) mobile robot, processing and transportation faults. The paper discusses also robustness issues, which are inevitable in real production systems. As a result, a novel robust predictive fault-tolerant strategy is developed that is applied to the battery assembly system. The last part of the paper shows illustrative examples, which clearly exhibit the performance of the proposed approach.

For several decades, a wide-spread consensus concerning the enormous importance of an in-depth clarification of the specifications of a product has been observed. A weak clarification of specifications is repeatedly listed as a main cause for the failure of product development projects. Requirements, which can be defined as the purpose, goals, constraints, and criteria associated with a product development project, play a central role in the clarification of specifications. The collection of activities which ensure that requirements are identified, documented, maintained, communicated, and traced throughout the life cycle of a system, product, or service can be referred to as “requirements engineering”. These activities can be supported by a collection and combination of strategies, methods, and tools which are appropriate for the clarification of specifications. Numerous publications describe the strategy and the components of requirements management. Furthermore, recent research investigates its industrial application. Simultaneously, promising developments of graph-based design languages for a holistic digital representation of the product life cycle are presented. Current developments realize graph-based languages by the diagrams of the Unified Modelling Language (UML), and allow the automatic generation and evaluation of multiple product variants. The research presented in this paper seeks to present a method in order to combine the advantages of a conscious requirements management process and graph-based design languages. Consequently, the main objective of this paper is the investigation of a model-based integration of requirements in a product development process by means of graph-based design languages. The research method is based on an in-depth analysis of an exemplary industrial product development, a gear system for so-called “Electrical Multiple Units” (EMU). Important requirements were abstracted from a gear system specification list and were analyzed in detail. As a second basis, the research method uses a conscious expansion of graph-based design languages towards their applicability for requirements management. This expansion allows the handling of requirements through a graph-based design language model. The first two results of the presented research consist of a model of the gear system and a detailed model of requirements, both modelled in a graph-based design language. Further results are generated by a combination of the two models into one holistic model.

Due to increasing sales figures, the energy consumption of battery-electric vehicles is moving further into focus. In addition to efficient driving, it is also important that the energy losses during AC charging are as low as possible for a sustainable operation. In many situations it is not possible or necessary to charge the vehicle with the maximum charging power e.g., in apartment buildings. The influence of the charging mode (number of phases used, in-cable-control-box or used wallbox, charging current) on the charging efficiency is often unknown. In this work, the energy consumption of two electric vehicles in the Worldwide Harmonized Light-Duty Vehicles Test Cycle is presented. In-house developed measurement technology and vehicle CAN data are used. A detailed breakdown of charging losses, drivetrain efficiency, and overall energy consumption for one of the vehicles is provided. Finally, the results are discussed with reference to avoidable CO${}_2$ emissions. The charging losses of the tested vehicles range from 12.79 to 20.42%. Maximum charging power with three phases and 16 A charging current delivers the best efficiencies. Single-phase charging was considered down to 10 A, where the losses are greatest. The drivetrain efficiency while driving is 63.88% on average for the WLTC, 77.12% in the “extra high” section and 23.12% in the “low” section. The resulting energy consumption for both vehicles is higher than the OEM data given (21.6 to 44.9%). Possible origins for the surplus on energy consumption are detailed. Over 100,000 km, unfavorable charging results in additional CO${}_2$ emissions of 1.24 t. The emissions for an assumed annual mileage of 20,000 km are three times larger than for a class A+ refrigerator. A classification of charging modes and chargers thus appears to make sense. In the following work, efficiency improvements in the charger as well as DC charging will be proposed.

In recent years, Automated Guided Vehicles (AGVs) have been playing an increasingly important role in producing industry and infrastructure and will soon arrive to other areas of human life such as the transportation of goods and people. However, several challenges still aggravate the operation of AGVs, which limit the amount of implementation. One major challenge is the realization of reliable sensors that can capture the different aspects of the state of an AGV as well as its surroundings. One promising approach towards more reliable sensors is the supplementary application of virtual sensors, which are able to generate virtual measurements by using other sources of information such as actuator states and already existing sensors together with appropriate mathematical models. The focus of the research described in this paper is the design of virtual sensors determining forces and torques acting on an AGV. The proposed novel approach is using a quadratic boundedness approach, which makes it possible to include bounded disturbances acting on the AGV. One major advantage of the presented approach is that the use of complex tire models can be avoided. Information from acceleration and yaw rate sensors is processed in order to realize reliable virtual force and torque sensors. The resulting force and torque information can be used for several diagnostic purposes such as fault detection or fault prevention. The presented approach is explained and verified on the basis of an innovative design of an AGV. This innovative design addresses another major challenge for AGVs, which is the limited maneuvering possibilities of many AGV designs. The innovative design allows nearly unlimited maneuvering possibilities but requires reliable sensor data. The application of the approach in the AGV resulted in the insight that the generated estimates are consistent with the longitudinal forces and torques obtained by a proven reference model.

The main focus of this paper is the integration of an integrated function modeling (IFM) framework in an engineering framework based on graph-based design languages (GBDLs). Over the last decade, GBDLs have received increasing attention as they offer a promising approach for addressing several important challenges in engineering, such as the frequent and time-consuming transfer of data between different computer aided engineering (CAE) tools. This absorbs significant amounts of manual labor in engineering design projects. GBDLs create digital system models at a meta level, encompassing all relevant information concerning a certain product design and feeding this into the relevant simulation tools needed for evaluating the impact of possible design variations on the performance of the resulting products/parts. It is possible to automate this process using digital compilers. Because of this, it is also possible to realize systematic design variations for a very large number of parameters and topological variants. Therefore, these kinds of graph-based languages are a powerful means for creating a large number of viable design alternatives and for permitting fast evaluation processes against the given specifications. While, thus far, such analyses tend to be based on a more or less fully defined system, this paper proposes an expansion of the applicability of GBDLs into the domain of product functions to cohesively link conceptual with embodiment design stages. This will also help with early systematic, automated generation and the validation of design alternatives through relevant simulation tools during embodiment design. Further, it will permit the automated exploration of function paths and enable extended analysis possibilities, such as the detection of functional bottlenecks, while enhancing the traceability of the design over the development process. For these extended analysis possibilities, a function analysis tool was developed that adopts core ideas of the failure mode and effects analysis (FMEA). In this, the functional distinction between function carriers and function-related processes allows the goal-directed assessment of component reliabilities and the detectability and importance of processes in a technical system. In the paper, the graph-based modeling of functions and the function analysis tools are demonstrated on the example of a multicopter.