networked production engineering (m.sc.)’ · 2020-01-24 · numerical and motion controls of...

Tentative Module Handbook for the Master’s Degree Course

‘Networked Production Engineering (M.Sc.)’

Track: Electric Mobility Production

1

Table of Contents

Compulsory Courses – First Semester .................................................................................................... 3

Program specific ........................................................................................................................................ 3

Module: Mechatronic and Control Techniques for Production Plants ................................................ 3

Module: Manufacturing Technology I ................................................................................................. 7

Compulsory Course – First and Second Semester .............................................................................. 10

Track specific ............................................................................................................................................ 10

Module: Battery Storage Systems .................................................................................................... 10

Elective Courses – First and Third Semester ........................................................................................ 15

Module: Advanced Software Engineering ........................................................................................ 15

Module: Modeling, Model Reduction and Simulation in Laser Processing - Applications ............... 18

Module: Tribology ............................................................................................................................. 22

Module: High Precision Glass Optics Manufacturing ....................................................................... 26

Module: Laser Applications .............................................................................................................. 30

Module: Simulation Techniques in Manufacturing Technology ....................................................... 34

Module: Process Analysis in Manufacturing Technology................................................................. 38

Module: Electrical Machines I .......................................................................................................... 42

Module: Power Electronics ............................................................................................................... 45

Module: Control Engineering ............................................................................................................ 48

Compulsory Course – First Semester .................................................................................................... 51

Language Course ..................................................................................................................................... 51

Module: Language Course (1) ......................................................................................................... 51

Compulsory Courses – Second Semester ............................................................................................. 53

Program specific ...................................................................................................................................... 53

Module: Manufacturing Technology II .............................................................................................. 53

Module: Production Management B ................................................................................................. 56

Compulsory and Elective Courses – Second Semester ....................................................................... 59

Track specific ............................................................................................................................................ 59

Module: Battery Production .............................................................................................................. 59

Module: Electric Mobility Components Production ........................................................................... 62

Module: Production of Electric Drives .............................................................................................. 65

Module: Welding and Joining Technologies .................................................................................... 68

Elective Courses – Second or Fourth Semester ................................................................................... 71

Module: Multibody Dynamics ........................................................................................................... 71

Module: Modeling, Model Reduction and Simulation in Laser Processing - Laser .......................... 75

2

Module: Modeling, Model Reduction and Simulation in Laser Processing - Design ....................... 79

Module: Factory Planning ................................................................................................................ 83

Module: Industrial product development process - battery systems for hybrid & electric vehicles .. 87

Module: Intelligent Monitoring of Engineering Systems ................................................................... 91

Compulsory Course – Second Semester ............................................................................................... 94

Language Course ..................................................................................................................................... 94

Module: Language Course (2) ......................................................................................................... 94

Compulsory Course – Third Semester ................................................................................................... 96

Program specific ...................................................................................................................................... 96

Module: Industrial Intelligence Interlaced Quality Management ...................................................... 96

Compulsory Course – Third Semester ................................................................................................. 100

Track specific .......................................................................................................................................... 100

Module: Gear and Transmission Technology ................................................................................ 100

Elective Courses – Third Semester ...................................................................................................... 103

Practicale Experiences or Elective Courses ....................................................................................... 103

Module: Internship .......................................................................................................................... 103

Compulsory Course – Third Semester ................................................................................................. 105

Language Course ................................................................................................................................... 105

Module: Linguistic Elective ............................................................................................................. 105

Compulsory Course – Fourth Semester .............................................................................................. 107

Master Thesis .......................................................................................................................................... 107

Module: Master Thesis ................................................................................................................... 107

3

Compulsory Courses – First Semester

Program specific

Module: Mechatronic and Control Techniques for Production Plants

Module Mechatronics and Control Techniques for Production Plants

Module level Master

Subtitle MCP

Lecture See list of lectures and examinations of the module

Semester allocation 1

Person in charge Univ.-Prof. Dr.-Ing. Christian Brecher

Lecturer Univ.-Prof. Dr.-Ing. Christian Brecher

Language English

Assignment to the

curriculum Compulsory module

Teaching form Written or oral examination, Lecture, Exercise

Workload Total 180h, Lecture hours 60h (4 SWS), Self-study 120h

Lecture hours 60h (4 SWS)

ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Mechatronics and Control Techniques for Production Plants

Overall goal: Students get familiar with the structure, the design and the

engineering process of mechatronic systems.

After successfully completing this course, the students will have acquired

the following learning outcomes:

Knowledge / Understanding

Students

understand the characteristics of the behavior and control of feed axes in machine tools;

4

know different types of sensors and their application within machine tools.

Abilities / Skills

Students

apply this knowledge to create control programs in different programming tools;

get to know the essential features and applications of logical,

numerical and motion controls of machines.

Content

Mechatronics and Control Techniques for Production Plants

Introduction to Mechatronics and control for production

Overview of mechatronic systems

Construction of feed drives

Information processing in mechatronic systems

Theory and examples of embedded systems

Programmable logic circuits

Measurement systems and sensors

Position and angle measuring systems

Acceleration and vibration measurement

Mechanical control

Single and multi-spindle turning machines

Further developments

Gripping technology

Gripping principles

Sensor technology and applications

Position control of feed drives

Control concept of a machine axis

Accuracy and synchronous control of multi-axis

Numerical Control 1: structure, programming, CAM

Construction of NC controls

NC programming process

Numerical Control 2: Interpolation

Kinematic transformations and compensations

Interpolation

Industrial robots and handling systems, robot control

Structure and kinematic transformations

RC programming

Programmable Logic Control (PLC) and motion control (MC)

Basics of Information Processing

Programmable Controllers

5

Signal processing, process and condition monitoring

Tasks of process and condition monitoring

Use of sensors and signal processing

Mechatronic Engineering, Simulation environments for virtual

commissioning

Basics of modeling of mechatronic systems

Behavior modeling and data management

Introduction: complexity of software and systems

Media e-Learning MOODLE, Power Point

Literature Lecture Notes

Students also receive a list of relevant literature

Lectures / Examinations

Title ECTS Workload

Duration of

Exam (min) Lecture h. (SWS) Self-Study (h)

Examination:

Mechatronics and

Control Techniques for

Production Plants

6 0 0

120 (written)

or max. 60

(oral)

Lecture:

Mechatronics and


Production Plants

0 2 60 0

Exercise:

Mechatronics and


Production Plants

0 2 60 0

Teaching Unit / Examinations: Examination Mechatronics and Control Techniques for

Production Plants

Title Examination Mechatronics and Control Techniques for Production Plants

Sub-title Exa MCT


Connection to the


Teaching Unit / Examinations: Lecture Mechatronics and Control Techniques for Production

Plants

Title Lecture Mechatronics and Control Techniques for Production Plants

Sub-title L MCT

6


Connection to the


Teaching Unit / Examinations: Exercise Mechatronics and Control Techniques for Production

Plants

Title Exercise Mechatronics and Control Techniques for Production Plants

Sub-title E MCT


Connection to the


7

Module: Manufacturing Technology I

Module Manufacturing Technology I

Module level Master

Subtitle MT I



Person in charge Univ.-Prof. Dr.-Ing. Thomas Bergs

Lecturer Univ.-Prof. Dr.-Ing. Thomas Bergs

Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Manufacturing Technology I




Students

have an in-depth insight on manufacturing technologies. They know and understand the comply principles of cutting, forming, material removal and additive manufacturing;

know and understand process parameters, cutting and forming criteria, tool and work piece characteristics.

Abilities / Skills

Students

8

apply this knowledge and are able to choose the right manufacturing processes with regard to geometrical and functional work piece properties.

estimate the effects of process parameter variations on forces, tool life, wear mechanisms and rim zone characteristics.

Competencies

Students

critically analyze company decisions with technological background and communicate the assessments to non-specialist audiences;

optimize manufacturing processes and assess possible consequences on part functionality.

Content


Introduction to manufacturing technology

Measuring and testing in manufacturing technology

Principles of machining with geometrically defined cutting

edges

Cutting criteria

Cutting materials, tools and lubricants

Applications of processes with defined cutting edge

Principles of cutting with undefined cutting edges

Grinding tools and grinding wheel preparation

Applications of processes with undefined cutting edge

Material removal manufacturing processes (EDM, ECM)

Laser and high pressure water jet machining

Additive manufacturing (RP, RT)

Media e-Learning, Power Point




Title ECTS Workload

Duration of


Examination:

Manufacturing

Technology I

5 0 0

90-120

(written) or

max. 60

(oral)

9

Lecture:

Manufacturing

Technology I

0 2 45 0

Exercise:

Manufacturing

Technology I

0 2 45 0

Teaching Unit / Examinations: Examination Manufacturing Technology I

Title Examination Manufacturing Technology I

Sub-title Exa MT I


Connection to the


Teaching Unit / Examinations: Lecture Manufacturing Technology I

Title Lecture Manufacturing Technology I

Sub-title L MT I


Connection to the


Teaching Unit / Examinations: Exercise Manufacturing Technology I

Title Exercise Manufacturing Technology I

Sub-title E MT I


Connection to the


10

Compulsory Course – First and Second Semester

Track specific

Module: Battery Storage Systems

Module Battery Storage Systems

Module level Master

Subtitle BSS


Semester allocation 1 and 2

Person in charge Univ.-Prof. Dr. rer. nat. Dirk Uwe Sauer

Lecturer Univ.-Prof. Dr. rer. nat. Dirk Uwe Sauer

Language English

Assignment to the


Teaching form Written examination, Presentation (Examination), Lecture, Exercise



ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Battery Storage Systems

This module gives a fundamental understanding for rechargeable

batteries and super caps.




Students

understand and apply basic principles of thermodynamics and kinetics of batteries;

11

understand the fundamental electrochemical processes in batteries;

understand the basic configuration of batteries and evaluate safety and electrical performance characteristics;

understand essential differences between lithium-ion batteries, lead-acid batteries and super caps.

Abilities / Skills

Students

evaluate different battery technologies;

calculate theoretical and practical energy density of batteries;

apply different approaches to modeling;

implement methods of battery diagnostics and modeling;

find an appropriate battery technology for a certain application and develop the battery pack design;

develop system solutions in group work;

give a speech about technical subjects.

Battery Storage Systems – Selected Laboratory Exercises

After successfully completing this course, the student will have acquired



Students

understand the typical electrical and electro-chemical behavior of batteries;

understand the design of batteries and the impact of the design on the performance;

understand the basics of battery modeling;

understand the basics of life cycle analysis for batteries.

Content

Battery Storage Systems

Determination of open circuit voltage via thermodynamic equations

Kinetics of batteries: ohmic resistances, butler-volmer equation, diffusion

Basic concepts of battery storage systems technology

Lithium-ion batteries, lead-acid batteries and super caps technology in detail: basic electrochemical setup and used materials, safety of different materials, electrical properties, current- and temperature dependencies, typical aging processes, charging and discharging behavior, deduction of appropriate

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battery management strategies, necessary components of battery management systems

System technical elements of battery packs: Design of chargers and charging method, Cell balancing systems, Thermal management, Modeling approaches, Basic algorithms for battery diagnostics, Protection of battery packs, Total integration of battery cells in battery packs

Approaches to accelerated lifetime tests

Training of presentation techniques

Battery Storage Systems – Selected Laboratory Exercises

# 1: Gasing and acid density of lead-acid batteries

# 2: Impedance spectroscopy and modelling of lead-acid batteries

# 3: Discharge characteristica of batteries

# 4: Diagnostics and balancing of Super caps

# 5: Load profiles of busses and electric vehicles

# 6: Electrochemical basics

# 7: Basic design of a battery cell

# 8: Modelling of Lithium-ion batteries

# 9: Fuel cells

# 10: Life Cycle Analysis





Title ECTS Workload

Duration of


Examination:

Battery Storage

Systems

4 0 0

90-120

(written), 25

(presentation)

Examination:

Battery Storage

Systems – Selected

Laboratory Exercises

1 0 0

4 Protocols of

Laboratory

Exercises (6-

10 pages)

Lecture:

Battery Storage

Systems

0 2 30 0

13

Exercise:

Battery Storage

Systems

0 1 15 0

Practical Session:

Battery Storage

Systems – Selected


0 1 15 0

Teaching Unit / Examinations: Examination Battery Storage Systems

Title Examination Battery Storage Systems

Sub-title Exa BSS


Connection to the


Teaching Unit / Examinations: Examination Battery Storage Systems – Selected Laboratory

Exercises

Title Examination Battery Storage Systems – Selected Laboratory Exercises

Sub-title Exa BSS - SLE


Connection to the


Teaching Unit / Examinations: Lecture Battery Storage Systems

Title Lecture Battery Storage Systems

Sub-title L BSS


Connection to the


Teaching Unit / Examinations: Exercise Battery Storage Systems

Title Exercise Battery Storage Systems

Sub-title E BSS


Connection to the


Teaching Unit / Examinations: Practical Session Battery Storage Systems – Selected


14

Title Practical Session Battery Storage Systems – Selected Laboratory

Exercises

Sub-title P BSS - SLE


Connection to the


15

Elective Courses – First and Third Semester

Module: Advanced Software Engineering

Module Advanced Software Engineering

Module level Master

Subtitle ASE


Semester allocation 1 or 3

Person in charge Univ.-Prof. Dr.-Ing. Christian Hopmann

Lecturer Dipl.-Inform. Daniel Lütticke

Language English

Assignment to the

curriculum Elective module




ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Advanced Software Engineering




Students

comprehend for what purposes, under which conditions and with which consequences computer systems are used for the solution of problems related to Mechanical Engineering;

gain a solid knowledge in the Software Development Life Cycle and the main activities and core concepts under each software development phase.

16

Abilities / Skills

Students

transfer the acquired knowledge in object oriented design to different engineering problems and understand the general structure and the functionality of software.

Content

Advanced Software Engineering

The aim of the course is to explain students for what purposes, under which conditions and with which consequences computer systems are used for the solution of problems related to Mechanical Engineering.

Within the first part of the course the steps from problem description to the final software solution are illustrated. This covers the topics modelling, problem elicitation and analysis, program design and an introduction to UML (Unified Modelling Language). Then the course goes on with a closer examination of the various aspects which comprise software development, concerning with topics like design patterns, agile software processes and project management. Parallel to the lecture the students are given the chance to employ the theoretical input from the course in small software projects. After an introduction to the basics of Java and object-oriented programming, the students stepwise pass through the particular stages of a software development process. Moreover, a part of the exercise is implemented by using physical robots.





Title ECTS Workload

Duration of


Examination:

Advanced Software

Engineering

5 0 0

90-120

(written) or

max. 60

(oral)

Lecture:

Advanced Software

Engineering

0 2 45 0

Exercise:

Advanced Software

Engineering

0 2 45 0

Teaching Unit / Examinations: Examination Advanced Software Engineering

Title Examination Advanced Software Engineering

Sub-title Exa ASE

17


Connection to the


Teaching Unit / Examinations: Lecture Advanced Software Engineering

Title Lecture Advanced Software Engineering

Sub-title L ASE


Connection to the


Teaching Unit / Examinations: Exercise Advanced Software Engineering

Title Exercise Advanced Software Engineering

Sub-title E ASE


Connection to the


18

Module: Modeling, Model Reduction and Simulation in Laser Processing - Applications

Module Modeling, Model Reduction and Simulation in Laser Processing - Applications

Module level Master

Subtitle MMRSLP-A


Semester 1 or 3

Person in charge Univ.-Prof. Dr. rer. nat. Wolfgang Schulz

Lecturer Univ.-Prof. Dr. rer. nat. Wolfgang Schulz

Language English

Assignment to the curriculum

Elective Module




ECTS-Credit Points (CP)

5

Requirements according to examination regulation

-none-

Learning objectives

Modeling, Model Reduction and Simulation in Laser Processing – Applications After successfully completing this course, the students will have acquired the following learning outcomes:


Free Boundary Problems and integral methods of solution,

non-linear stability analysis using spectral methods,

analysis of the structural stability of model equations and

5 parameter pairs of optical material equations, transmission, reflection, absorption, Fresnel Formulae, polarisation of matter and radiation

Learning target 2: optical parameters

Slow surfaces in dynamical Systems: applications

for separation of time scales

19

Learning target 6: Thermal effect of large and small Peclet-number,

know and understand the 5 different, dominant phenomena of drilling, welding and cutting with laser radiation

Learning target 5: quality features

know the physical meaning of the terms contained in the Navier-Stokes equations for mass, momentum, and energy balance

know the main properties of the solution in the asymptotic case of thin film flow (boundary layer) and can explain the relation between dynamical properties of the solution and quality features of the product as well as productivity of the process for drilling and cutting

know the effect of dissipation in distributed dynamical systems (inertial manifold) and know examples for the application of methods for the reduction of the dimension in dissipative systems, understand and perform the separation of length and time scales in simple systems

Learning target 7: heating and melting phase of ablation

understand the interactive cooperation of scientists from engineering, physics and mathematics for application of model based methods for diagnosis in laser processing Learning target 8: reduced modelling

Abilities / Skills

Application of model based methods for solving practical tasks from discussion of project examples

Content

Modeling, Model Reduction and Simulation in Laser Processing – Applications

Overview of contents, definition of the 10 learning targets

the contribution of the engineer to the interactive cooperation of

scientific disciplines

main features of the theory of cognition (Karl Popper)

recapitulation of the 10 learning targets from Module I: Laser

Learning target 1: at least 10 industrial applications of laser

radiation

Learning target 2: reduced model of the Fresnel Formulae for the

limiting case of small displacement current, optical parameters

technical task and examples:

cutting with laser radiation

Learning target 3: quality features of the high quality cut

physical task of cutting and identification of quality defined

processing domains

Learning target 4: relation of physical phenomena to the built up

of quality degradations

technical task and examples:

drilling with laser radiation

physical task formulation and 5 dominant phenomena

Learning target 5: quality features of the drilled hole

mathematical modelling Ia: length and time scales

20

degrees of freedom in phase space of dependent variables

separation of time scales in simple dynamical systems

Learning target 6a: separation of time scales

mathematical modelling Ib: singular perturbation and asymptotic

expansion

thermal boundary layer in heat conduction with moving

boundaries

Learning target 6b: separation of length scales

mathematical modelling II:

Free Boundary Problems (FBP) for the solid phase

reduced model for the FBP :

motion of the melting front, integral methods, variational

formulation

Learning target 7: heating and melting phase of ablation

mathematical modelling III: Meta-Modelling

Morse-Smale-Complex

Learning target 8: reduced model of drilling and cutting

mathematical model reduction: melt flow

reduced model for thin film flow

Learning target 9: ripple and dross formation in cutting

model reduction and solution with controlled error:

melt flow at low Reynolds-number

structural stability of the reduced model:

lubrication approximation, fingering and droplet formation

global properties of the solution of balance equations for mass,

momentum and thermal energy – example: cutting

Learning target 10: scales for parameter estimation in laser

processing

parameters in cutting and drilling

concluding discussion of the learning targets

actual research and development of laser processing

Media Presentations, Laboratory: Data acquisition and analysis software

Literature Lecture Notes, List of relevant literature


Title ECTS

Workload (SWS / h) Duration of Exam (min) Lecture h. (SWS) Self-Study (h)

Exam: Modeling, Model Reduction and Simulation in Laser Processing – Applications

5 0 0

Max. 60 (oral) or 120 (written)

Lecture: Modeling, Model Reduction and

0 2 45 0

21

Simulation in Laser Processing – Applications

Exercise: Modeling, Model Reduction and Simulation in Laser Processing – Applications

0 2 45 0

Teaching Unit / Examinations: Examination Modeling, Model Reduction and Simulation in Laser Processing – Applications

Title Examination Modeling, Model Reduction and Simulation in Laser Processing – Applications

Sub-title Exa MMRSLP-A

Semester 1 or 3

Connection to the curriculum

Elective Module

Teaching Unit / Examinations: Lecture Modeling, Model Reduction and Simulation in Laser Processing – Applications

Title Lecture Modeling, Model Reduction and Simulation in Laser Processing – Applications

Sub-title L MMRSLP-A

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Exercise Modeling, Model Reduction and Simulation in Laser Processing – Applications

Title Exercise Modeling, Model Reduction and Simulation in Laser Processing – Applications

Sub-title E MMRSLP-A

Semester 1 or 3


Elective Module

22

Module: Tribology

Module Tribology

Module level Master

Subtitle TB



Person in charge Univ.-Prof. Dr.-Ing. Georg Jacobs

Lecturer Univ.-Prof. Dr.-Ing. Georg Jacobs

Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Tribology




Students

know fundamental mechanisms in the contact zone of tribosystems:

hydrodynamics

material deformation

tribological stress

fluid / solid body friction

wear

Abilities / Skills

23

Students

employ the fundamental theories to design and analyze tribosystems;

design tribosystems in mechanical systems, like journal bearings, roller bearings, gear wheels and seals.

Competencies

Students

are capable of choosing and applying different suitable measuring- and test systems to investigate the tribosystems of journal bearings, roller bearings, gear wheels and seals;

are capable of choosing and applying different suitable calculation and simulation methods to investigate the tribosystems of journal bearings, roller bearings, gear wheels and seals;

are capable of estimating the quality of the tribosystem according to the test and simulation results and to optimize it with the background knowledge of a considerably large action catalogue;

design the tribosystems of the mechanical components of drive trains;

minimize friction and wear in mechanical drive trains. In that way, they can enhance the resource and energy efficiency of drive train systems.

Content

Tribology

Basics of tribology:

• Tribosystem in general and its analysis

• Wear and friction processes

• Test methods

Interactions between base and contact bodies:

• Contact processes and geometries, material strain, Hertzian theory,

contact mechanics

• Frictional processes and the results and influence on the tribosystem,

wear processes and methods to avoid wear and losses

Properties of base and contact bodies:

• Tribomaterials and the analysis of technical surfaces, roughness,

hardness definitions and test methods

• Coating types and methods and their technical application, systematical

methods and examples for the correct choice of material

Properties of intermediate medium:

• Basic properties, dependencies and test methods for the viscosity

• Classification, properties and application examples for different

lubricants (oils, greases and solid lubricants)

Basics of hydrodynamics and elastohydrodynamics:

• Fundamentals and principles of flow mechanisms, derivation of Navier-

Stokes and Reynolds equations and continuity equation

24

• Application of the hydrodynamic equations regarding the calculation of

bearings

• Basics of the elastohydrodynamics

Tribosystem journal bearings:

• Functionality and calculation of hydrodynamic axial and radial journal

bearings

• Damages and failures of hydrodynamic journal bearings

• Choice of suitable lubricants for hydrodynamic journal bearings

• Functionality and calculation of hydrostatic axial and radial journal

bearings

• Damages and failures of hydrostatic journal bearings

• Choice of suitable lubricants for hydrostatic journal bearings

Tribosystem gear wheels:

• Lubricants and materials for gears and their influence and application

• Application of the EHD-theory for gear stages

• Damages and failures of gear wheels and suitable test methods for the

analysis of gear stages

Tribosystem roller bearings:

• Design, materials and lubrication for roller bearings

• Friction, damages and failures for roller bearings

• Test methods for the analysis of roller bearings

Tribosystem seals:

• Different types and designs of seals

• Specialties and application of different seals

• Materials for seals





Title ECTS Workload

Duration of


Examination:

Tribology 5 0 0

120 (written)

or max. 60

(oral)

Lecture:

Tribology 0 2 45 0

Exercise:

Tribology 0 2 45 0

Teaching Unit / Examinations: Examination Tribology

25

Title Examination Tribology

Sub-title Exa TB


Connection to the


Teaching Unit / Examinations: Lecture Tribology

Title Lecture Tribology

Sub-title L TB


Connection to the


Teaching Unit / Examinations: Exercise Tribology

Title Exercise Tribology

Sub-title E TB


Connection to the


26

Module: High Precision Glass Optics Manufacturing

Module High Precision Glass Optics Manufacturing

Module level Master

Subtitle HPGOM


Semester 1 or 3


Lecturer Dr.-Ing. Olaf Dambon

Language English


Elective Module



Lecture hours 4 SWS


6


Recommended: Manufacturing Technology I

Learning objectives

High Precision Glass Optics Manufacturing Overall goal: Ability to layout and develop process chains for the production of highly precise glass optics under given industrially relevant aspects and technological constraints After successfully completing this course, the students will have acquired the following learning outcomes:


Students:

know and understand the demands on precision components;

know and understand the specialities of glass in comparison to other materials;

know and understand direct machining and replication methods for complex optical lens production;

27

know and understand the characteristics of ultra-precision machine tools for machining optical components.

Abilities / Skills

Students:

Apply this knowledge and are able to assess manufacturing processes, machine tools and metrology methods with regard to the demands of optical components;

Are able to evaluate production strategies for higher quality, higher output, higher complexity and lower costs.

Competencies

Students:

critically analyze company decisions with a technological background and communicate the assessments to non-specialist audiences;

are familiar with the latest production trends in the seminal optics branch.

Content

High Precision Glass Optics Manufacturing

LE 1 (Introduction): Clear overview on the topic and the following courses, Application cases, Awareness for the need of high precision optics

LE 2 (Machine Aspects): Awareness of requirements on UP machines in comparison to non-UP machines, tribological aspects, error origins/impacts/compensation strategies

LE 3 (Grinding I): Awareness of the needs of grinding, machining, distinction between brittle and ductile machining, rendition of ELID sequences

LE 4 (Grinding II): Classification of different materials regarding their machinability by grinding, grinding wheel indications, assign wheel composition to the application

LE 5 (Polishing of glass optics I): Distinction between grinding, polishing, lapping and honing, working principle, influence on the removal rate

LE 6 (Polishing of glass optics II): Full-aperture, sub-aperture and corrective polishing, corrective polishing principles, mechanical and chemo-mechanical polishing

LE 7 (Diamond Turning): Distinction between grinding/polishing and diamond turning, achievable accuracy, impossibility of direct steel SPDT, wear mechanisms and prevention

28

LE 8 (Coatings): Coatings and their applications, optical and wear protective coatings, differences between coating technologies, AR-coatings, wear mechanisms and prevention

LE 9 (Modeling): Simulation assistance in molding processes, concepts/mathematics, chances and limits, critical interpretation of simulation results

LE 10 (Non-isothermal Glass Molding): Precision and efficiency, working principle, heat transfer mechanisms, knowledge of wear phenomena and influence sources

LE 11 (Precision Glass Molding): Classifying PGM regarding precision and efficiency, understanding of the working principle (temperatures, motions, etc.) esp. in comparison to NGM, Knowledge of wear phenomena and influence sources

LE 12 (Metrology): Measuring principles and application, complex shape measurements, tactile and non-tactile shape qualification, interferometry, validity of measuring results

LE 13 (Application Case): Recapitulation of the »big picture«, approaching manufacturing problems systematically, evaluation of direct or replicative manufacturing depending on applications and markets

Media -

Literature

Klocke, F.; König, W. Fertigungsverfahren 2 – Zerspanung mit geometrisch unbestimmter Schneide, Springer Vieweg, 5. Auflage, 2018;

Klocke, F.; König, W. Fertigungsverfahren 4 – Umformen, Springer Vieweg, 6. Auflage, 2018;

Bliedtner, J.; Gräfe, G. Optiktechnologie. Grundlagen – Verfahren – Anwendungen – Beispiele. München, Fachbuchverl. Leipzig (Carl-Hanser-Verl.), 2008;

Weck, M., Brecher, C. (Hrsg.) Werkzeugmaschinen. Vol. 1 – 4, Berlin Heidelberg, Springer Press, 2005;

Bach, H.; Neuroth, N. (Hrsg.) The Properties of Optical Glass. Berlin/Heidelberg, Springer-Verlag, 1995


Title ECTS


Examination: High Precision Glass Optics Manufacturing

6 0 0 15 (oral) or 120 (written)

29

Lecture: High Precision Glass Optics Manufacturing

0 2 3 0

Exercise: High Precision Glass Optics Manufacturing

0 2 3 0

Teaching Unit / Examinations: Examination High Precision Glass Optics Manufacturing

Title Examination High Precision Glass Optics Manufacturing

Sub-title Exa HPGOM

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture High Precision Glass Optics Manufacturing

Title Lecture High Precision Glass Optics Manufacturing

Sub-title L HPGOM

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Exercise High Precision Glass Optics Manufacturing

Title Exercise High Precision Glass Optics Manufacturing

Sub-title E HPGOM

Semester 1 or 3


Elective Module

30

Module: Laser Applications

Module Laser Applications

Module level Master

Subtitle LAP



Person in charge Univ.-Prof. Dr. rer. nat. Reinhart Poprawe

Lecturer Univ.-Prof. Dr. rer. nat. Reinhart Poprawe, tbd

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

31

Learning objectives

Laser Applications

Overall goal: Students gain basic knowledge about the generation,

characteristics and applications of laser radiation.




Students

understand the generation and properties of laser radiation;

know the fundamentals of light-matter interaction, heat transport and phase transitions;

gain knowledge about laser-based processing and manufacturing (like hardening, joining, drilling, cutting and additive manufacturing) and further fields of laser application (like measurement technology).

Abilities / Skills

Students

are able to evaluate manufacturing processes in order to identify those that benefit from the use of laser radiation;

can apply mathematical techniques to identify and optimise process-specific laser beam parameters.

Competencies

Students

are able to identify suitable laser parameters for specific tasks in materials processing;

can identify a laser source providing the desired parameters for a given process;

are able to work on current research problems, e.g. within a Master’s thesis.

Content

Laser Applications

The laser principle

Properties of laser radiation (spectral, temporal and spatial)

Laser types and systems

Reflection, absorption, transmission

Temperature, heat conduction, mass diffusion and melt pool dynamics

Laser-based surface treatment

32

Additive Manufacturing

Joining

Cutting

Ablation

Measurement technology


Literature

Lecture notes

R. Poprawe, K. Boucke, D. Hoffmann: Tailored Light 1 (Springer Verlag,

2018)

R. Poprawe: Tailored Light 2 (Springer Verlag, 2011)

Students receive a list of relevant literature


Title ECTS Workload

Duration of


Examination:

Laser Applications 6 0 0

120 (written)

or 30 (oral)

Lecture:

Laser Applications 0 2 60 0

Exercise:

Laser Applications 0 2 60 0

Teaching Unit / Examinations: Examination Laser Applications

Title Examination Laser Applications

Sub-title Exa LA


Connection to the


Teaching Unit / Examinations: Lecture Laser Applications

Title Lecture Laser Applications

Sub-title L LA


Connection to the


Teaching Unit / Examinations: Exercise Laser Applications

33

Title Exercise Laser Applications

Sub-title E LA


Connection to the


34

Module: Simulation Techniques in Manufacturing Technology

Module Simulation Techniques in Manufacturing Technology

Module level Master

Subtitle STMT


Semester 1 or 3


Lecturer Dr.-Ing. Mustapha Abouridouane

Language English


Elective Module

Teaching form Written or oral examination, Lecture , Exercise




6


Recommended requirements (e.g., other modules, foreign language skills):

Englisch in word and writing


Learning objectives

Simulation Techniques in Manufacturing Technology Overall goal: Teaching theory and practise in modelling and simulation of manufacturing processes After successfully completing this course, the students will have acquired the following learning outcomes:


Students:

Revision of the fundamentals of materials science and manufacturing technology

Introduction to the basic methods of modeling and simulation of manufacturing processes

Procedure and application of the finite element method for the simulation of manufacturing processes

Possibilities and limits of modeling and simulation

35

Application of the simulation software DEFORM and ABAQUS for the simulation of different manufacturing processes

Abilities / Skills

Students:

independently select appropriate simulation methods for manufacturing processes and prove their selection on a scientific basis;

set up and evaluate an FE simulation.

Competencies

Students:

develop their own modelling approaches for manufacturing processes and to formulate them in research questions as well as to incorporate them in development activities.

Content

Simulation Techniques in Manufacturing Technology

Lecture 1: In the first lecture an introduction to the topic "Simulation Techniques in Manufacturing Technology" will be given

Lecture 2: The contents of the second lecture are the basic aspects and processes of forming technology

Lecture 3: After the student has learned the basics of forming technology, this lecture will focus on current simulation techniques during forming

Lecture 4: The fourth lecture deals with fundamental aspects and the simulation of sheet metal forming

Lecture 5: The fifth lecture gives an introduction to the basics and simulation methods of punching and fine blanking processes

Lecture 6: Contents of the sixth lecture are the principles of cutting processes

Lecture 7: Lecture 7 gives a general overview of different cutting processes

Lecture 8: One possibility to model cutting processes is the finite element method (FEM). This lecture shows various current examples of the FE simulation of cutting processes

Lecture 9: The ninth lecture gives an introduction to cutting with an undefined cutting edge

Lecture 10: Lecture 10 introduces current modeling methods for grinding

Lecture 11: In lecture 11 special attention will be paid to the methods of validation and optimization techniques

36

Lecture 12: The content of the last lecture is to learn in small groups the preparation and evaluation of FE machining simulation with the FE code ABAQUS

Media Power-Point Presentation, Movies, FE Software

Literature

Script of Manufacturing Technology I (For sale at WZL)

Script of Manufacturing Technology II (For sale at WZL)

S. Kobayashi, T. Altan, S. Kobayashi: Metal Forming and the Finite-Element Method, Oxford Series on Advanced Manufacturing, Oxford University Press, 1989

T. Childs: Metal Machining (Theory and Applications), ISBN-13: 978-0340691595

K. Cheng: Machining Dynamics (Fundamentals, Applications and Practices), ISBN: 978-1-84628-367-3


Title ECTS

Workload (SWS / h)

Duration of Exam (min) Lecture h.

(SWS) Self-Study (h)

Examination: Simulation Techniques in Manufacturing Technology


Lecture: Simulation Techniques in Manufacturing Technology

0 2 70 0

Exercise: Simulation Techniques in Manufacturing Technology

0 1 65 0

Teaching Unit / Examinations: Examination Simulation Techniques in Manufacturing Technology

Title Examination Simulation Techniques in Manufacturing Technology

Sub-title Exa STMT

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture Simulation Techniques in Manufacturing Technology

37

Title Lecture Simulation Techniques in Manufacturing Technology

Sub-title L STMT

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Exercise Simulation Techniques in Manufacturing Technology

Title Exercise Simulation Techniques in Manufacturing Technology

Sub-title E STMT

Semester 1 or 3


Elective Module

38

Module: Process Analysis in Manufacturing Technology

Module Process Analysis in Manufacturing Technology

Module level Master

Subtitle PAMT


Semester 1 or 3


Lecturer Dr.-Ing. Guido Wirtz

Language English


Elective Module





5


Recommended: Manufacturing Technology I

Learning objectives

Process Analysis in Manufacturing Technology Overall goal: Ability to analyse manufacturing processes Students understand how process and workpiece properties can be measured and analysed. They get to know metrology as an essential part of modern production processes. After successfully completing this course, the students will have acquired the following learning outcomes:


Setup, functionality and application of technical sensors for the analysis of manufacturing processes

Components of a measuring chain, functionality, connection of the elements and estimation of the measuring deviation

Options on signal analysis of stationary and instationary processes in time and frequency domain

39

Characteristics of manufacturing technologies which require a scientific analysis

Abilities / Skills

Students are able to choose suitable measurement systems, to integrate them into manufacturing processes, to acquire and analyse the signals. In the laboratory, they gain the practical experience, which is required to apply the theoretical knowledge. Students are able to arrange the setup of a measuring chain, data acquisition in LabView and data analysis in the software Diadem.

Competencies

The students recognize correlations between process and part characteristics and can make conclusions on the part’s quality. Furthermore, they recognize the impact of metrology on manufacturing processes, which results from the integration of certain measurement systems. They are able to describe changes of dynamical systems and critically evaluate these changes.

Content

Process Analysis in Manufacturing Technology

Introduction on the scope of the course to go for the elective or not

Fundamentals:

Technical sensors: Strain, force, acceleration, acoustic emission, temperature, pressure, viscosity, clouding, moisture

Measuring chain : Components, setup, signal conditioning, analog-to-digital, parameterization, measuring deviation, application software LabView

Signal analysis: Time and frequency domain, bandwidth, spectral resolution, aliasing, analysis of stationary and instationary processes, application software Diadem

Applications:

Turning: Force, acceleration, temperature and wear measurement, force and wear modelling, self-induced and forced vibrations, residual stress measurement, thin film integrated sensors

Drilling: Force, acceleration, temperature and wear measurement, telemetry, force and wear modelling, short and deep hole drilling, monitoring of the chip removal, scaling of force and torque at small diameters

Milling: Interrupted cut, dynamical system analysis, transfer function, stability theory , force and acceleration measurement

Grinding: Grinding burn, nital etching, Barkhausen noise, adaptive grinding, sensor assisted dressing and balancing

Powder metallurgy: Powder classification, analysis of the porosity distribution, non- destructive testing methods

Laser material processing: Beam quality and caustic measurement, power measurement in the continuous and pulsed wave mode, weld seam tracing and triangulation

40

Forming and blank cutting: Integration of force and distance sensors in forming and cutting tools, tribological effects, measurement of pressure, temperature, viscosity and clouding of hydraulic oils

Material removal technologies: Measurement of high-frequency voltage and current impulses, application of measurement systems in electromagnetically polluted environments, force and distance measurement in micro EDM sinking, passivation layer thickness measurement in ELID grinding

Media Presentations, Laboratory: Data acquisition and analysis software

Literature

Klocke, F.; König, W.: Manufacturing Processes 1, 1st Ed., 2011




Title ECTS


Exam: Process Analysis in Manufacturing Technology


Lecture: Process Analysis in Manufacturing Technology

0 2 70 0

Exercise: Process Analysis in Manufacturing Technology

0 1 35 0

Teaching Unit / Examinations: Examination Process Analysis in Manufacturing Technology

Title Examination Process Analysis in Manufacturing Technology

Sub-title Exa PAMT

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture Process Analysis in Manufacturing Technology

Title Lecture Process Analysis in Manufacturing Technology

Sub-title L PAMT

Semester 1 or 3

41


Elective Module

Teaching Unit / Examinations: Exercise Process Analysis in Manufacturing Technology

Title Exercise Process Analysis in Manufacturing Technology

Sub-title E PAMT

Semester 1 or 3


Elective Module

42

Module: Electrical Machines I

Module Electrical Machines I

Module level Master

Subtitle EM I


Semester 1 or 3

Person in charge Univ.-Prof. Dr.-Ing. Dr.h.c. dr hab. Kay Hameyer

Lecturer Univ.-Prof. Dr.-Ing. Dr.h.c. dr hab. Kay Hameyer

Language English


Elective Module





4


-none-

Learning objectives

Electrical Machines I After successfully completing this course, the students will have acquired the following learning outcomes:


have an understanding of the electromagnetic energy conversion;

know the topology of the electromagnetic circuit, which is suitable for the energy conversion;

obtain the knowledgement of the construction, mode of operation and the stationary operating characteristics of the electrical machines.

Abilities / Skills

can follow the physical effect of voltage induction and are able to transfer it into practical situations.

Content Electrical Machines I

43

Transformator: Construction and mode of operation, equivalent circuit diagram, voltage equations, operating behavior, three-phase transformer.

DC machine: Structure and method of operation, armature winding, induced voltage, torque, voltage equation, operational behavior as motor and generator (separately excited , shunt excited, permanently excited, series excitation, compound excitation), commutation, armature inductions.

Rotating field theory: Structure of a rotary current generator, alternating flux, rotating flux, three-phase ac winding, turns rate, induced voltage, torque, rotary field performance. Asynchronous machine: Equivalent circuit diagram, Calculation of inductances and resistances, Operational behavior, Circle diagram, Technical requirements, Squirrel-cage rotor, Displacement rotor, Rotating speed adjustment, Initial behavior, Asynchronous generator (induction generator)

Synchronous machine: Equivalent circuit diagram, Pointer diagram, Turbo generator, Salient-pole generator, Idling cycle, Sustained short-circuit, Isolated plant, Operation at the rigid network, permanently excited synchronous machines, Clawpolegenerator, external-pole synchronous generator.

Small machines for one-phase operation: Universal motor, Single-phase operation of the three-phase alternating current asynchronous machine, One-phase asynchronous engine operation, Shaded-pole motor. Application and technical design of electrical machines.





Title ECTS


Exam: Electrical Machines I


Lecture: Electrical Machines I

0 2 50 0

Exercise: Electrical Machines I

0 1 25 0

Teaching Unit / Examinations: Examination Electrical Machines I

Title Examination Electrical Machines I

44

Sub-title Exa EM I

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture Electrical Machines I

Title Lecture Electrical Machines I

Sub-title L EM I

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Exercise Electrical Machines I

Title Exercise Electrical Machines I

Sub-title E EM I

Semester 1 or 3


Elective Module

45

Module: Power Electronics

Module Power Electronics

Module level Master

Subtitle PE


Semester 1 or 3

Person in charge Univ.-Prof. Dr.ir. Dr.h.c. Rik W. De Doncker

Lecturer Univ.-Prof. Dr.ir. Dr.h.c. Rik W. De Doncker

Language English


Elective Module





4


-none-

Learning objectives

Power Electronics After successfully completing this course, the students will have acquired the following learning outcomes:


understand topologies for power electronic applications.

Abilities / Skills

Understand the working principle of different power converters;

Analyze the dynamic behavior of components and circuits, and their basic control concepts;

Design/ size main component in a power conversion system.

Content Power Electronics

46

Power electronic converters perform the conversion of electrical energy

with high efficiency. The course focuses on the following aspects of

converter design:

Semiconductors and analysis

Line-Commutated converters

Inductor and transformer analysis

Design, control and modulation of dc-dc converters

Self-commutated converters

Pulse width modulation





Title ECTS


Exam: Power Electronics


Lecture: Power Electronics

0 2 50 0

Exercise: Power Electronics

0 1 25 0

Teaching Unit / Examinations: Examination Power Electronics

Title Examination Power Electronics

Sub-title Exa PE

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture Power Electronics

Title Lecture Power Electronics

Sub-title L PE

Semester 1 or 3

47


Elective Module

Teaching Unit / Examinations: Exercise Power Electronics

Title Exercise Power Electronics

Sub-title E PE

Semester 1 or 3


Elective Module

48

Module: Control Engineering

Module Control Engineering

Module level Master

Subtitle CE


Semester 1 or 3

Person in charge Univ.-Prof. Dr.-Ing. Dirk Abel

Lecturer Univ.-Prof. Dr.-Ing. Dirk Abel

Language English


Elective Module





3


Basic knowledge in mathematics as defined in the examination regulations.

Learning objectives

Control Engineering After successfully completing this course, the students will have acquired the following learning outcomes:


know, recognize and classify the most common linear control loop elements;

know the effects of feedback and apply different methods to set up feedback elements (controllers) such that predefined control goals are met.

Abilities / Skills

analyze dynamical, biological and biomedical systems and identify the relevant causalities;

employ different mathematical descriptions of dynamical systems;

solve differential equations by means of Laplace transform;

49

assess of the stability of dynamical systems using different methods;

obtain, interpret and employ the frequency response of dynamical systems.

Content

Control Engineering

Significance of control theory, examples of biological and biomedical

control loops, functional diagrams, linearization, set up and solving of

differential equations, stability, features in time domain of dynamical

systems, Laplace transform, transfer function, frequency response,

functional diagram algebra, features in frequency domain of dynamical

systems, bode diagram, Nyquist plot, Linear control loop elements,

principle and goals of controller design, algebraic stability criteria, steady

state analysis and transient performance of a control loop, controller

setting rules, Nyquist stability criterion, phase margin, gain margin,

controller design in bode diagram.


Literature Lecture Notes, List of relevant literature


Title ECTS


Exam: Control Engineering

3 0 0

Max. 60 (oral) or 120 (written)

Lecture: Control Engineering

0 1 30 0

Exercise: Control Engineering

0 1 30 0

Teaching Unit / Examinations: Examination Control Engineering

Title Examination Control Engineering

Sub-title Exa CE

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Lecture Control Engineering

Title Lecture Control Engineering

Sub-title L CE

50

Semester 1 or 3


Elective Module

Teaching Unit / Examinations: Exercise Control Engineering

Title Exercise Control Engineering

Sub-title E CE

Semester 1 or 3


Elective Module

51

Compulsory Course – First Semester

Language Course

Module: Language Course (1)

Module Language Course (1)

Module level Master

Subtitle LC 1



Person in charge RWTH Aachen University Language Center

Lecturer -

Language German (if not proficient/native speaker)

Assignment to the


Teaching form Written examination, Lecture, Exercise



ECTS-Credit Points

(CP) 2

Requirements

according to

examination

regulation

-none-


Title ECTS Workload

Duration of


Examination:

Language Course (1) 2 0 0

60-90 min.

written

Lecture:

Language Course (1) 0 1 15 0

Exercise:


Teaching Unit / Examinations: Language Course (1)

52

Title Examination Language Course (1)

Sub-title Exa LC (1)


Connection to the



Title Lecture Language Course (1)

Sub-title L LC (1)


Connection to the


Teaching Unit / Examinations: Exercise Language Course (1)

Title Exercise Language Course (1)

Sub-title E LC (1)


Connection to the


53

Compulsory Courses – Second Semester

Program specific

Module: Manufacturing Technology II

Module Manufacturing Technology II

Module level Master

Subtitle MT II





Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Manufacturing Technology II




Students

have an extended understanding in technologically comprehensive topics like material science and tribology;

know and understand the mechanisms to improve the performance of powder metallurgical, cutting, forming and hybrid processes.

54

Abilities / Skills

Students

apply this knowledge properly and are able to assess manufacturing processes with regard to near surface damages and functional surfaces;

evaluate processes by calculation of key figures for productivity, profitability and reliability und thus are able to propose solutions.

Content

Manufacturing Technology II

Metal-based Materials

Tool Materials

Powder Metallurgy

Tribology

Near Surface Damages and Functional Surfaces

High-Speed Machining

Bulk and Sheet Metal Forming

Computer-aided Technology Planning

Hybrid Manufacturing Methods

Productivity and Profitability

Manufacturing of Optical Components

Manufacturing of Components for Mobility

Manufacturing Methods for Toolmaking





Title ECTS Workload

Duration of


Examination:

Manufacturing

Technology II

6 0 0

120 (written)

or max. 60

(oral)

Lecture:

Manufacturing

Technology II

0 2 60 0

Exercise:

Manufacturing

Technology II

0 2 60 0

Teaching Unit / Examinations: Examination Manufacturing Technology II

55

Title Examination Manufacturing Technology II

Sub-title Exa MT II


Connection to the


Teaching Unit / Examinations: Lecture Manufacturing Technology II

Title Lecture Manufacturing Technology II

Sub-title L MT II


Connection to the


Teaching Unit / Examinations: Exercise Manufacturing Technology II

Title Exercise Manufacturing Technology II

Sub-title E MT II


Connection to the


56

Module: Production Management B

Module Production Management B

Module level Master

Subtitle PM B



Person in charge Univ.-Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh

Lecturer Univ.-Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh

Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Production Management B




Students

know and understand particular aspects of the domains design, process planning, production as well as program planning and investment planning;

understand the usefulness of modern planning methods, with emphasis on the application of computers (CAD, CAP, CAM etc.;

understand the boundary conditions in daily business and give the students an advanced and comprehensive basis to reflect advantages and disadvantages of the discussed systems.

Abilities / Skills

57

Students

analyse the structure of enterprise resources, make comparisons and give recommendations according to the results of the analysis.

Content

Production Management B

• IT in Production Management

• Customer Relations Management

• Enterprise Resource Planning I

• Enterprise Resource Planning II

• Enterprise Resource Planning III

• Supply Chain Management I

• Supply Chain Management II

• Product Lifecycle Management I

• Product Lifecycle Management II

• Product Lifecycle Management III

• Digital Plant Planning and Simulation

• Business Engineering - Method of selecting IT-Systems





Title ECTS Workload

Duration of


Examination:

Production

Management B

5 0 0

90-120

(written) or

max. 60

(oral)

Lecture:

Production

Management B

0 2 45 0

Exercise:

Production

Management B

0 2 45 0

Teaching Unit / Examinations: Examination Production Management B

Title Examination Production Management B

Sub-title Exa PM B


58

Connection to the


Teaching Unit / Examinations: Lecture Production Management B

Title Lecture Production Management B

Sub-title L PM B


Connection to the


Teaching Unit / Examinations: Exercise Production Management B

Title Exercise Production Management B

Sub-title E PM B


Connection to the


59

Compulsory and Elective Courses – Second Semester

Track specific

Module: Battery Production

Module Battery Production

Module level Master

Subtitle BP


Semester 2


Lecturer Dr.-Ing. Dipl.-Wirt.-Ing. Heiner Hans Heimes

Language English


Elective Module



Lecture hours 30


3


- None -

Learning objectives

Battery Production Overall goal: Students gain basic knowledge about battery systems and lithium-ion battery production. After successfully completing this course, the students will have acquired the following learning outcomes:


The lecture provides students with a comprehensive overview of the functioning, production and value structures in battery production. Students can apply this knowledge in various areas and apply it to future problems. The performance, cell design and safety requirements arising

60

from the electrification of the drive train of vehicles are examined in more detail.

Abilities / Skills / Competencies

After completing the in-depth elective lecture, students are familiar with the diversity of electrical storage systems and know the strengths and weaknesses of individual technologies. The focus of the lecture is on the individual aspects of lithium ion technology and its application. The lecture units (LU) Electrode Production, Cell Production, Formation and Aging and Quality Assurance convey in detail the manufacturing process of three different format types of lithium ion cells and their properties. The lecture unit (LU) Module and pack production allows an insight into the electrical connection of individual cells, their temperature control and integration into the final application. The Lecture Unit (LU) Safety Tests explains the dangers and safety requirements of lithium-ion batteries. Safety relevant standards and tests for their testing are dealt with in particular. The lecture unit (LU) Factory Planning describes the requirements for building and plant engineering for the production of lithium-ion cells. The lecture units (LU) Value Creation Structures Europe and Recycling deal with the raw material situation for the production of lithium ion batteries, the legal requirements for recycling and the existing approaches for the recycling of lithium ion batteries.

Content

Battery Production

Introduction to the functioning of energy storage systems

Overview of energy storage systems

Applications of energy storage systems

Electrode manufacture

Cell production

Formation and aging

Quality assurance

Module and pack production

Safety tests

Factory planning

Value creation structures Europe

Recycling



Students also receive a list of relevant literature.


Title ECTS Workload (SWS / h)

61

Lecture h. (SWS) Self-Study (h) Duration of Exam (min)

Examination: Battery Production

3 0 0

90 (written) or max. 60 (oral)

Lecture: Battery Production

0 1 30 0

Exercise: Battery Production

0 1 30 0

Teaching Unit / Examinations: Examination Battery Production

Title Examination Battery Production

Sub-title Exa BP

Semester 2


Elective Module

Teaching Unit / Examinations: Lecture Battery Production

Title Lecture Battery Production

Sub-title L BP

Semester 2


Elective Module

Teaching Unit / Examinations: Exercise Battery Production

Title Exercise Battery Production

Sub-title E BP

Semester 2


Elective Module

62

Module: Electric Mobility Components Production

Module Electric Mobility Components Production

Module level Master

Subtitle EMCP


Semester 2

Person in charge Prof. Dr.-Ing. Achim Kampker, MBA

Lecturer Dr.-Ing. Christoph Deutskens M.Eng.

Language English


Elective Module



Lecture hours 30


3


none

Learning objectives

Electric Mobility Components Production Overall goal: The lecture gives students a comprehensive overview of the production of E-mobility components and focuses on practical aspects, which are presented in detail. The challenges for vehicle and plant construction arising from the electrification of the powertrain are examined more closely. After successfully completing this course, the students will have acquired the following learning outcomes: Knowledge / Understanding

Students:

understand the specific challenges of electric mobility components production;

are familiar with the production processes of the electric motor, the battery and the fuel cell of modern electric vehicles;

are familiar with the recycling management and 2nd use applications from battery systems

63

understand quality-relevant aspects relating to the manufacturing processes

know the change in value creation structures between conventional and electric driven vehicles.

Abilities / Skills

Students:

find the best solutions for production process technologies of electric vehicle components;

know the specific challenges of battery electric vehicles and are able to identify the best industrialization strategy.

Competencies

Students:

find solutions for best production technologies under the specific boundary conditions of production of electric vehicle components;

find solutions for designing production process capacities in production of electric motor, battery, fuel cell of electric vehicles.

find solutions for recycling and remanufacturing of batteries.

Content

Electric Mobility Components Production

In the lecture unit (LU) "Introduction to E-mobility components production (ECP)" the basics of electric vehicle production are presented and an overview of the essential changes in the automotive industry caused by the introduction of electric vehicles is provided. The LU "Value Added Structures in ECP" examines not only the new value added steps but also the relationship between automobile manufacturers and suppliers. New business models and mobility services are addressed. The "Battery Cell Production" and "Battery Module and Pack Production" LU deal with the individual production and assembly processes of the individual battery cell through to the assembly of the entire high-voltage accumulator. In the LU "Electric Motor Production" the basics of the electric motor are presented and the entire production process of the individual components is illustrated. In the LU "Production of Drive Systems", the product and process technologies of electric drive units and their subsystems are discussed. The "Fuel Cell Production" LU explains the basics of fuel cells for mobile applications and associated hydrogen storage systems. The focus is on the production and assembly of individual components as well as fuel cell stacks and fuel cell systems. In the LU "Quality and Test Processes in ECP", quality-relevant aspects relating to the manufacturing process are examined. The "Recycling Processes" LU deals with recycling management from battery system manufacturing to 2nd use applications as well as remanufacturing and recycling. The LU "Cost Structures and Investment Needs" deals with the new cost structures arising from the changed drive train. The "Industrialization Processes" LU describes the path from the product idea to series production. The LU "Perspectives of Future Production Processes" offers an outlook on the requirements of future production processes.

Media e-Learning L²P, PowerPoint



64


Title ECTS


Examination: Electric Mobility Production

3 0 0


Lecture: Electric Mobility Production

0 1 22.5 0

Exercise: Electric Mobility Production

0 1 22.5 0

Teaching Unit / Examinations: Examination Electric Mobility Components Production

Title Examination Electric Mobility Components Production

Sub-title Exa EMCP

Semester 2


Elective Module

Teaching Unit / Examinations: Lecture Electric Mobility Components Production

Title Lecture Electric Mobility Components Production

Sub-title L EMCP

Semester 2


Elective Module

Teaching Unit / Examinations: Exercise Electric Mobility Components Production

Title Exercise Electric Mobility Components Production

Sub-title E EMCP

Semester 2


Elective Module

65

Module: Production of Electric Drives

Module Production of Electric Drives

Module level Master

Subtitle PED


Semester 2


Lecturer Dipl.-Ing. Kai Kreisköther

Language English


Elective Module



Lecture hours 30


3


none

Learning objectives

Production of Electric Drives Overall goal: The lecture provides students with a comprehensive overview of the production of electric vehicles and sets practical focal points, which are dealt with in detail. The process steps and plant technology required for the production of electric drives are examined in more detail and the characteristic challenges are explained. After successfully completing this course, the students will have acquired the following learning outcomes: Knowledge / Understanding

Students:

understand the process steps and plant technology required for the production of electric drives;

are familiar with the characteristics and challenges of the production of electric drives;

66

know the basics of the economic efficiency of the production of electric drives.

Abilities / Skills

Students:

apply their acquired knowledge to problems within the production of electric drives as well as in other industrial fields.

Competencies

Students:

choose appropriate production technologies for specific production scenarios of electric drives;

apply their acquired problem-solving skills in a variety of industries.

Content

Production of Electric Drives

Introduction: Challenges in electric motor production

Basics of electrical machines

Material production (magnets, electrical sheet, enamelled wire)

Production of sheet metal packages

Rotor production

Basics of winding technologies

Stator production

Production and integration of power electronics and transmissions

Assembly process and final assembly of electric drives

Test processes and quality assurance

Scalability in electric motor production

Economic efficiency in electric motor production

Media e-Learning L²P, PowerPoint




Title ECTS


Examination: Production of Electric Drives

3 0 0


67

Lecture: Production of Electric Drives

0 1 22.5 0

Exercise: Production of Electric Drives

0 1 22.5 0

Teaching Unit / Examinations: Examination Production of Electric Drives

Title Examination Production of Electric Drives

Sub-title Exa PED

Semester 2


Elective Module

Teaching Unit / Examinations: Lecture Production of Electric Drives

Title Lecture Production of Electric Drives

Sub-title L DEP

Semester 2


Elective Module

Teaching Unit / Examinations: Exercise Production of Electric Drives

Title Exercise Production of Electric Drives

Sub-title E PED

Semester 2


Elective Module

68

Module: Welding and Joining Technologies

Module Welding and Joining Technologies

Module level Master

Subtitle WJT



Person in charge Univ.-Prof. Dr.-Ing. Uwe Reisgen

Lecturer Univ.-Prof. Dr.-Ing. Uwe Reisgen

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Welding and Joining Technologies

Welding is an interdisciplinary technology. All fields of industrial

manufacturing require the joining of individual parts to functional groups.

Many welding and cutting technologies are applicable for this purpose.

After successfully completing this course, the student will have acquired



Students

understand the main welding technologies and know how to critically review the shown welding technologies.

Abilities / Skills

Students

69

select the suitable welding technologies for a welding task and to substantiate the selection by specifying the advantages and the disadvantages of the individual methods.

Content

Welding and Joining Technologies

Introduction

Welding of steel

Gas Fusion Welding

Manual Metal Arc Welding

Submerged Arc Welding

TIG Welding

Plasma Welding

MIG Welding

Electro Gas Welding

Electro Slag Welding

Pressure Welding

Resistance Welding

Electron Beam Welding

Laser Beam Welding

Special Processes

Mechanization / Automation

Sensor Technology

Brazing

Mechanical Joining / Adhesive Bonding

Design and Calculation





Title ECTS Workload

Duration of


Examination:

Welding and Joining

Technologies

6 0 0

90-120

(written) or

max. 60

(oral)

Lecture:

Welding and Joining

Technologies

0 2 60 0

Exercise:

Welding and Joining

Technologies

0 2 60 0

70

Teaching Unit / Examinations: Examination Welding and Joining Technologies

Title Examination Welding and Joining Technologies

Sub-title Exa WJT


Connection to the


Teaching Unit / Examinations: Lecture Welding and Joining Technologies

Title Lecture Welding and Joining Technologies

Sub-title L WJT


Connection to the


Teaching Unit / Examinations: Exercise Welding and Joining Technologies

Title Exercise Welding and Joining Technologies

Sub-title E WJT


Connection to the


71

Elective Courses – Second or Fourth Semester

Module: Multibody Dynamics

Module Multibody Dynamics

Module level Master

Subtitle MD



Person in charge Univ.-Prof. Dr.-Ing. Dr. h. c. (UPT) Burkhard Corves

Lecturer Univ.-Prof. Dr.-Ing. Dr. h. c. (UPT) Burkhard Corves

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Multibody Dynamics




Students

have a profound knowledge of theory of vibrations;

are capable of comprehending, describing and analyzing vibratory systems;

are familiar with the most important matrix based procedures for the calculation of eigen motions and the behaviour of linear systems under forced excitations;

72

select suitable program systems for the calculation of nonlinear system and carry out proper simulations.

Abilities / Skills

Students

describe mathematically any mechanical system with its inherent physical effects like elasticity, damping and friction;

properly interpret simulation results especially under consideration of simplifications within the model compared to the real system.

Competencies

Students

derive from their knowledge the necessary methods and proceedings for the analysis and synthesis of the systems in regard. Thus they are capable to solve - accessing their acquired theoretical knowledge - complex problems concerning the choice and design of industrial vibratory systems.

Content

Multibody Dynamics

Introduction

Fundamentals

Fields of application

Model Building

Methods of Approach for Equivalent Models Multi-body Systems Determination of the Model Parameters General mathematical description

Kinematics of Multi Body Systems

Position and Orientation of Bodies Translational Kinematics Rotational Kinematics Equations of Motion

Lagrangian Equations of 2nd Kind Newton-Euler equations Linearisation Eigen Value Approach Undamped non-gyroscopic systems Damped gyroscopic systems Eigen Value Stability Criteria

Linear Systems with Harmonic Excitation

Real Frequency Matrix Complex Frequency Matrix State Equation System Matrix Eigen Value Approach Fundamental Matrix Modal Matrix

73

Theorem of Cayley-Hamilton Analytical Solution Numerical Solution Step Excitation Harmonic Excitation Periodical Excitation

Introduction of Multi Body Simulation Software

ADAMS SIMPACK SimMechanics

Hands-On-Laboratory for Multi Body Simulation Software

ADAMS SIMPACK SimMechanics

Example Modelling Determination of Parameters Calculation

Evaluation





Title ECTS Workload

Duration of


Examination:

Multibody Dynamics 6 0 0

120 (written)

or max. 60

(oral)

Lecture:

Multibody Dynamics 0 2 60 0

Exercise:

Multibody Dynamics 0 2 60 0

Teaching Unit / Examinations: Examination Multibody Dynamics

Title Examination Multibody Dynamics

Sub-title Exa MD


Connection to the


74

Teaching Unit / Examinations: Lecture Multibody Dynamics

Title Lecture Multibody Dynamics

Sub-title L MD


Connection to the


Teaching Unit / Examinations: Exercise Multibody Dynamics

Title Exercise Multibody Dynamics

Sub-title E MD


Connection to the


75

Module: Modeling, Model Reduction and Simulation in Laser Processing - Laser

Module Modeling, Model Reduction and Simulation in Laser Processing - Laser

Module level Master

Subtitle MMRSLP-L





Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Modeling, Model Reduction and Simulation in Laser Processing -

Laser




Students

experimental evidence of Maxwell equations

refraction, diffraction and scattering, Fresnel- number Nf, and applications

can perform the derivation of SVE-approximation

Laser light, can perform the calculation imaging and focussing

know at least 3 types of laser systems, temporal and spatial distribution of laser radiation, Fresnel-number, invariant quantity of light propagation

76

understand the structure of solution for the Helmholtz-equation, diffraction, 5 parameter pairs of optical material equations, transmission, reflection, absorption, Fresnel Formulae, polarisation of matter and radiation

know the main properties of the solution in the asymptotic case of paraxial light propagation and can explain the relation between optical and material parameters

know the effect of coupling between atoms and can explain the relation between band structure and optical properties

understand the interactive cooperation of scientists from engineering, physics and mathematics for application of model based methods for diagnosis in laser processing

Abilities / Skills

Students

Application of model based methods for solving practical tasks of laser design from discussion of project examples

Content


Laser

Overview of contents, definition of the 10 learning targets

• the contribution of the engineer to the interactive cooperation of scientific

disciplines

• main features of the theory of cognition (Karl Popper)

• Light:

amplitude and phase, Fermat’s principle, laser radiation, Helmholtz

equation, diffraction, Fresnel- number Nf,, reduced model: SVE-

approximation

• Learning target 1: experimental origin of Maxwell equations, Rayleigh

scattering, Laser Principle

• Learning target 2: ABCD-matrix, ABCD-law

• Learning target 3:

beam parameter product, optical invariant

• Matter:

emission spectra, band structure, reflection, transmission and absorption

of light,

• Learning target 4: isolator, semiconductor, metal, gas

• Learning target 5: Rydberg constant, Planck’s law

• Learning target 6: reduced model of the Fresnel Formulae for the limiting

case of small displacement current, optical parameters

• Gaussian Beam:

beam quality, beam guiding and forming

• Learning target 7: quality features of light, Plane-, spherical- and Gouy-

phase

77

Quality number K and focussing F-number

• Resonator:

frequency filter, axial mode structure

• Learning target 8: feedback-axial mode structure, g-parameter, aperture-

lateral mode, Fresnel number Nf, rod and tube design

• Active Medium:

entropy, phase transition of 2. Kind, Einstein rate equations

• Learning target 9: Gas and Solid-state and Diode Laser

• Learning target 10: laser threshold, cooling, pumping

• Modulation:

Gain switch µs, Q-Switch ns, Mode locking fs

• Learning target 11: phase coupling

• concluding discussion of the learning targets

• actual research and development of laser processing





Title ECTS Workload

Duration of


Examination:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Laser

5 0 0

90-120

(written) or

max. 60

(oral)

Lecture:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Laser

0 2 45 0

Exercise:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Laser

0 2 45 0

Teaching Unit / Examinations: Examination Modeling, Model Reduction and Simulation in

Laser Processing - Laser

Title Examination Modeling, Model Reduction and Simulation in Laser

Processing - Laser

78

Sub-title Exa MMRSLP-L


Connection to the


Teaching Unit / Examinations: Lecture Modeling, Model Reduction and Simulation in Laser

Processing - Laser

Title Lecture Modeling, Model Reduction and Simulation in Laser Processing -

Laser

Sub-title L MMRSLP-L


Connection to the


Teaching Unit / Examinations: Exercise Modeling, Model Reduction and Simulation in Laser

Processing - Laser

Title Exercise Modeling, Model Reduction and Simulation in Laser Processing -

Laser

Sub-title E MMRSLP-L


Connection to the


79

Module: Modeling, Model Reduction and Simulation in Laser Processing - Design

Module Modeling, Model Reduction and Simulation in Laser Processing - Design

Module level Master

Subtitle MMRSLP-D





Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives


Design

Overall goal: Students gain theoretical and practical knowledge to design

laser processes by understanding laser induced phenomena and the

needs of use to meet the performance suited to current and future

markets demand.




Students

Design of Research is based on formulation of a research question followed by research hypothesis, state of the art, contributions of theory and experiment;

80

Design Thinking for laser specification and laser processes by formulating specific research hypothesis leading to Reduced Models using the methods: 1. Dimensional Analysis, 2. Dimensionless groups, 3. Inertial Manifolds and Central Manifolds, 4. Length scale analysis and time scale separation;

know how to adapt laser properties to high performance processing;

understand the interactive cooperation of scientists from engineering, physics and mathematics for application of model based methods for diagnosis in laser processing.

Abilities / Skills

Students

apply model based methods for solving practical tasks of laser design.

Content

Modeling, Model Reduction and Simulation in Laser Processing –

Design

Overview of contents, definition of the 4 methodological (M1-M4) and 5

laser specific (L1-L5) learning targets:

Learning target M1 - Cooperation Engineering: the contribution of the

engineer to the

interactive cooperation of scientific disciplines (“Flowchart” approach)

Learning target M2 - Meta-Modelling: main features of the theories for

“design thinking” by

“meta-modelling” are

model reduction methods MRM:

mathematical, empirical and numerical approaches

global approximation and optimization methods

sensitivity analysis and hierarchical models

Learning target M3 - model reduction methods MRM:

Buckingham’s Pi-Theorem(mathematical MRM)

Model hierarchy threshold (empirical MRM))

Kriging global approximation versus response surface

(numerical MRM)

Proper orthogonal decomposition POD(numerical MRM)

Learning target M4 - mathematical MRM:

Analysis of dissipative distributed systems

applied to standard examples

Time scale separation (Inertial manifolds)

Singular perturbation

Learning target L1 – heating and melting phenomena

Laser Polishing (Marangoni effect, evaporation)

Learning target L2 - evaporation phenomena

Laser induced thermal stress analysis

Laser driven EUV-Sources (Extreme Ultra-Violet EUV)

81

Laser Propulsion - Light Engine

Learning target L3 - linear excitation phenomena

Laser Induced Fluorescence (LIF): biological carrier for TNT

detection

Learning target L4 - nonlinear Multi-Photon phenomena

Laser Fila mentation – Kerr effect, Multi-photon absorption

Multi-Photon Lithography

Learning target L5 - Coherence phenomena

Optical Coherence Tomography (OCT)

Particle detection (PIV, LDV, DGV, FRS)

Laser Interferometer Space Antenna (LISA)

Laser Time Measurement - Frequency Comb

Physical Limits related to energy manipulation (Laser Fusion, Laser

Cooling)

Concluding discussion of the learning targets and

Actual research and development of laser processing





Title ECTS Workload

Duration of


Examination:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Design

5 0 0

90-120

(written) or

max. 60

(oral)

Lecture:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Design

0 2 45 0

Exercise:

Modeling, Model

Reduction and

Simulation in Laser

Processing - Design

0 2 45 0

Teaching Unit / Examinations: Examination Modeling, Model Reduction and Simulation in

Laser Processing - Design

Title Examination Modeling, Model Reduction and Simulation in Laser

Processing - Design

82

Sub-title Exa MMRSLP-D


Connection to the


Teaching Unit / Examinations: Lecture Modeling, Model Reduction and Simulation in Laser

Processing - Design

Title Lecture Modeling, Model Reduction and Simulation in Laser Processing -

Design

Sub-title L MMRSLP-D


Connection to the


Teaching Unit / Examinations: Exercise Modeling, Model Reduction and Simulation in Laser

Processing - Design

Title Exercise Modeling, Model Reduction and Simulation in Laser Processing -

Design

Sub-title E MMRSLP-D


Connection to the


83

Module: Factory Planning

Module Factory Planning

Module level Master

Subtitle FP



Person in charge Univ.-Prof. Dr.-Ing. Dipl.-Wirt.-Ing. Achim Kampker

Lecturer Univ.-Prof. Dr.-Ing. Dipl.-Wirt.-Ing. Achim Kampker

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Factory Planning

The lecture factory planning shows the state of the art of the particular

topics. Best-practice methods and approaches are explained and

reference solutions presented.




Students

know and understand the main scope and challenges of factory planning projects;

understand the basic principles and methods of the factory planning modules which are presented in the lectures goal definition & product/ process analysis, location planning & plant structure planning, industrial facility & building design, production structure planning & capacity planning, layout planning &

84

workstation design, production logistics planning & production control, personnel planning & change management, implementation planning & ramp-up management and project management.

Abilities / Skills

Students

apply the gained knowledge to assess different factory planning solutions in industrial practice;

develop own factory planning concepts of lower complexity within the presented modules;

solve factory planning problems independently.

Competencies

Students

participate in factory planning projects and collaborate with other planners;

cope with the high complexity in factory planning projects and are able to develop creative solutions.

Content

Factory Planning

L1/L2 - Introduction

Comprehending the basic glossary, getting to know the content and

understanding the challenges and requirements of modern factory

planning and learn about the Aachen Factory Planning Methodology.

L3/L4 - Definition of goals and Product and process analysis

Getting to know methods for the definition of goals in early planning

phases. Comprehending basic methods for the analysis of product and

processes.

L5/L6 – Location planning and plant structure planning

The lecture focusses on the basic criteria for the selection of a specific

plant location and methods for the planning of the particular plant

structure.

L7/8 – Industrial facility and Building design

Getting to know the basic processes within industrial facility and building

design and learning about different building concepts.

L9/10 - Production structure planning and Capacity planning

Introduction to production structure planning with an explanation of

different concepts, understanding methods for the quantitative planning of

production capacities and resources.

85

L11/12 - Layout planning and Workstation design

Introduction to challenges and targets of layout planning and acquiring

knowledge of design and assessment of factory layouts. Getting to know

basic targets and methods for the design of single workstations.

L13/L14 - Production logistics planning and Production control

Comprehend the basics of logistics planning, getting to know the

development of logistic strategies and principles from sourcing to recycling

processes and learning about basic principles in production control.

L15/16 - Personnel planning and change management

Introduction to personnel planning with its specific challenges and

methods, learning about problems and solution approaches within change

management processes.

L17/18 - Implementation planning and ramp-up management

Getting to know basic methods of implementation planning and

understanding challenges within the ramp-up of new products. Learning

about tools and methods within ramp-up management.

L19/20 - Project management

Understanding basic methods and principles within project management for the project planning and project execution & controlling.





Title ECTS Workload

Duration of


Examination:

Factory Planning 6 0 0

120 (written)

or max. 60

(oral)

Lecture:

Factory Planning 0 2 60 0

Exercise:

Factory Planning 0 2 60 0

Teaching Unit / Examinations: Examination Factory Planning

Title Examination Factory Planning

Sub-title Exa FP

86


Connection to the


Teaching Unit / Examinations: Lecture Factory Planning

Title Lecture Factory Planning

Sub-title L FP


Connection to the


Teaching Unit / Examinations: Exercise Factory Planning

Title Exercise Factory Planning

Sub-title E FP


Connection to the


87

Module: Industrial product development process - battery systems for hybrid and electric vehicles

Module Industrial product development process - battery systems for hybrid and

electric vehicles

Module level Master

Subtitle FP



Person in charge Dr.-Ing. Hartung Wilstermann

Lecturer Dr.-Ing. Hartung Wilstermann

Language English

Assignment to the





ECTS-Credit Points

(CP) 5

Requirements

according to

examination

regulation

-none-

Learning objectives

Industrial product development process - battery systems for hybrid

and electric vehicles

The students learn how to assimilate and process complex system

interrelationships. The development and production of high voltage battery

packs for hybrid and electric vehicles is used as an example of the

product development process.

They learn how to deal with vaguely formulated questions, how to use the

freedoms this opens up and how to find creative ways of solving

problems. During complex assignments they learn how to structure a

complex issue, how to split up the overall problem and then bring it

together again into a joint solution.



88


Students

have an understanding of the industrial product development process

understand the complete process chain

Abilities / Skills

Students

apply basic procedures in development, quality assurance, product qualification and production

set up market analyses and cost efficiency analyses

prepare specifications for battery packs and develop them taking into account the safety standards, industrial quality assurance procedures and the required production engineering

Competencies

Students

independently build a complete process chain

independently manage a complete industrial product development process in a practical setting

Content

Industrial product development process - battery systems for hybrid

and electric vehicles

Formulation of the requirements for vehicle batteries (among others package, weight, safety, costs, development time); development of specifications from these requirements, taking into account the standards and safety regulations relevant to the market; definition of key performance indicators for the development of vehicle batteries.

Measures and procedures for quality assurance and maintaining safety standards (e.g. ASIL – all levels) together with methods and processes for achieving these standards (including the V-model, concepts for developing secure software and its evaluation, etc.)

Fundamentals of costing and cost efficiency analyses on the basis of the parts lists, taking into account purchasing processes in the automotive industry and the production process.

Procedures for systematic competition and market analysis, patent and license research procedures, preparation of a dedicated portfolio of proprietary rights.

Product development of high voltage battery packs with full functionality incl. battery management system, thermal management and active/passive safety measures.

Development and optimization of the production process, definition of the machines and the level of automation, establishment of the logistic chains with vendors and semi-finished products.

Program of tests and trials to ensure functionality, the fulfilment of guarantee periods and all safety requirements.

89

Product Design

Requirement

Preparation of Specification

Development

PDP

A,B,C,D samples

Testing and simulation

Production planning

Tolerance management

Process FMEA

Requirements of the production facilities

Production start-up

Test bench technology – ensuring a zero defect product

Ramp-up of a production line and its optimization

Series production support

Quality and vendor management

Diagnosis

Quality control loops

Media e-Learning, Power Point




Title ECTS Workload

Duration of


Examination:

Industrial product

development process -

battery systems for

hybrid and electric

vehicles

5 0 0 max. 45

(oral)

Lecture:

Industrial product


battery systems for

hybrid and electric

vehicles

0 2 45 0

90

Exercise:

Industrial product


battery systems for

hybrid and electric

vehicles

0 2 45 0

Teaching Unit / Examinations: Industrial product development process - battery systems for

hybrid and electric vehicles

Title Examination Industrial product development process - battery systems for


Sub-title Exa IPDP


Connection to the


Teaching Unit / Examinations: Lecture Industrial product development process - battery

systems for hybrid and electric vehicles

Title Lecture Industrial product development process - battery systems for


Sub-title L IPDP


Connection to the


Teaching Unit / Examinations: Exercise Industrial product development process - battery

systems for hybrid and electric vehicles

Title Exercise Industrial product development process - battery systems for


Sub-title E IPDP


Connection to the


91

Module: Intelligent Monitoring of Engineering Systems

Module Intelligent Monitoring of Engineering Systems

Module level Master

Subtitle IMES


Semester 2

Person in charge Univ.-Prof. Dr.-Ing. Bernd Markert

Lecturer Univ.-Prof. Dr.-Ing. Bernd Markert; Daniel Hesser; Arnd Koeppe

Language English


Elective Module

Teaching form Written and oral examination (Exam; Written/Oral Examination: 80%

Presentation: 20%), Lecture (L), Exercise (E)

Workload Total 150h, Lecture hours: 3 SWS

Lecture hours 3 SWS


5


Programming experience, particularly in Python and/or Matlab, is recommended.

Learning objectives

Intelligent Monitoring of Engineering Systems The students will get an overview over current trends in structural health monitoring (SHM) and understand their theoretical foundation in the context of engineering applications After successfully completing this course, the students will have acquired the following learning outcomes:


Students:

Are familiar with sensing systems, filtering methods and computational intelligence

Abilities / Skills

Students:

92

analyze engineering, mainly mechanical, systems and to monitor the relevant system parameters

apply fundamental methods of structural health monitoring

Competencies

Students:

transfer their knowledge to new engineering applications in science and industry.

independently plan, advance and complete research in the Monitoring of Engineering Systems

Content

Intelligent Monitoring of Engineering Systems

The course “Intelligent Monitoring of Engineering Systems” is available for

students enrolled in the Master programmes of RWTH Aachen University.

It provides insights into recent monitoring strategies, which are closely

linked to the field of structural health monitoring and computational

intelligence. The course will be taught interactively, engaging the students

using practical example projects.

The following topics are covered:

+ Sensing and Data acquisition

- Sensors

- Sensing Systems

+ Data Preparation

- Filtering

- Feature Engineering

+ Classification and Learning

+ Structural Health Monitoring

+ Predictive Maintenance

+ Case Studies

The course curriculum consists of interactive seminar lectures

accompanied by semester project works. During the seminar lectures, the

students will receive the necessary theoretical information and supervision

to independently plan, advance and complete the projects in small groups.

In addition, the seminars offer the opportunity to discuss challenges and

problems arising during the course of the projects. Finally, the

achievements and results obtained within the student projects will be

presented by the students in the scope of the seminar lectures and the

accompanying computer lab exercises.


Literature

Farrar, C.R. and Worden, K., 2012. Structural Health Monitoring: A Machine Learning Perspective. Wiley.

Lecture Notes, Slides


93


Title Code ECTS

Workload (SWS / h) Duration of Exam (min)

Lecture h. (SWS)

Self-Study (h)

Examination: Intelligent Monitoring of Engineering Systems

5 0 0

60 min. written or 30 min. oral

Lecture: Intelligent Monitoring of Engineering Systems

0 2 55 0

Exercise: Intelligent Monitoring of Engineering Systems

0 1 40 0

Teaching Unit / Examinations: Intelligent Monitoring of Engineering Systems

Title Examination Intelligent Monitoring of Engineering Systems

Sub-title Exam IMES

Semester 2


Elective Module


Title Lecture Intelligent Monitoring of Engineering Systems

Sub-title L IMES

Semester 2


Elective Module


Title Exercise Intelligent Monitoring of Engineering Systems

Sub-title E IMES

Semester 2


Elective Module

94

Compulsory Course – Second Semester

Language Course

Module: Language Course (2)

Module Language Course (2)

Module level Master

Subtitle LC 2




Lecturer -

Language German (if not proficient/native speaker)

Assignment to the





ECTS-Credit Points

(CP) 2

Requirements

according to

examination

regulation

-none-


Title ECTS Workload

Duration of


Examination:

Language Course (2) 2 0 0

60-90 min.

written

Lecture:


Exercise:


95


Title Examination Language Course (2)

Sub-title Exa LC (2)


Connection to the



Title Lecture Language Course (2)

Sub-title L LC (2)


Connection to the


Teaching Unit / Examinations: Exercise Language Course (2)

Title Exercise Language Course (2)

Sub-title E LC (2)


Connection to the


96

Compulsory Course – Third Semester

Program specific

Module: Industrial Intelligence Interlaced Quality Management

Module Industrial Intelligence Interlaced Quality Management

Module level Master

Subtitle iQM



Person in charge Univ.-Prof. Dr.-Ing. Robert Schmitt

Lecturer Univ.-Prof. Dr.-Ing. Robert Schmitt

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Industrial Intelligence Interlaced Quality Management

Professional and methodical competence:

The students develop an operational understanding of the different forms

of the concept of quality and classify them with regard to "industrial

intelligence". They are able to identify and classify problems in the

corporate context. They have basic knowledge in the field of machine

learning, are familiar with related advanced quality management methods

and can describe their specific applicability and effectiveness.

Application competence:

Students will be able to understand applications in the quality

management domain with the help of the theoretical and practical

knowledge imparted. They are able to build up the structure of an

97

"industrial intelligence" in the company context by means of quality

management methods, to evaluate its effectiveness and to further develop

and to connect methods of quality management.

Competence to act:

On the basis of their sound methodological and organizational knowledge,

the students are able to intervene in value chains in order to improve

them. They can recognize and evaluate situations, strengths and

weaknesses of an existing quality management system and formulate

suitable measures for further development.




Students

know important standards and guidelines in "Quality Management" and understand the structure of standards (High-Level Structure)

distinguish between system, process and product quality;

recognize quality-relevant data and data sources along the product life cycle;

explain statistical and methodological basics of "Industrial Intelligence" as a central task of quality management

understand basic data analytics and machine learning methods

know the legal implications

understand the concept of Internet of Production

understand the importance of quality and quality management in networked, adaptive production

name the classification of typical problems

Abilities / Skills

Students

apply data collection (e.g. gain customer insights in the product development process and during product use, data-driven procurement management);

apply of selected data analytics and machine learning methods (e.g. tor risk quantification and analyse problematic quality issues: prediction, process control)

organize quality management for services

undertake decision support of the "Smart Quality Expert" (e.g. Predictive Quality, Predictive Maintenance)

Competencies

Students

98

critically assess topics such as quality planning, quality costs and quality legal questions via discussions;

critically reflect approaches, methods and guiding principles while

communicating their opinions.

Content

Industrial Intelligence Interlaced Quality Management

The module is based on the research content of the "Internet of

Production" cluster of excellence. Against this background, the

participants should take the intellectual transformation step from the

application of tools (methodological competence) to the shaping of the

underlying principles and interrelations in value chains (action

competence).





Title ECTS Workload

Duration of


Examination:

Industrial Intelligence

Interlaced Quality

Management

6 0 0

120 (written)

or max. 60

(oral)

Lecture:


Interlaced Quality

Management

0 2 60 0

Exercise:


Interlaced Quality

Management

0 2 60 0

Teaching Unit / Examinations: Examination Industrial Intelligence Interlaced Quality

Management

Title Examination Industrial Intelligence Interlaced Quality Management

Sub-title Exa iQM


Connection to the


Teaching Unit / Examinations: Lecture Industrial Intelligence Interlaced Quality Management

99

Title Lecture Industrial Intelligence Interlaced Quality Management

Sub-title L iQM


Connection to the


Teaching Unit / Examinations: Exercise Industrial Intelligence Interlaced Quality Management

Title Exercise Industrial Intelligence Interlaced Quality Management

Sub-title E iQM


Connection to the


100


Track specific

Module: Gear and Transmission Technology

Module Gear and Transmission Technology

Module level Master

Subtitle GTT



Person in charge Univ.-Prof. Dr.-Ing. Christian Brecher

Univ.-Prof. Dr.-Ing. Thomas Bergs

Lecturer Univ.-Prof. Dr.-Ing. Christian Brecher

Univ.-Prof. Dr.-Ing. Thomas Bergs

Language English

Assignment to the





ECTS-Credit Points

(CP) 6

Requirements

according to

examination

regulation

-none-

Learning objectives

Gear and Transmission Technology




Students

learn about the requirements on modern gears;

know the basics of calculation and test methods that are used in the development process of gears;

101

understand how test rigs for fatigue and gear noise tests will be introduced;

get knowledge about the gear production and the machine tools for gear production.

Abilities / Skills

Students

gain experience in simulation techniques in gear design and corresponding manufacturing processes;

gain experience in the analysis of gear tests.

Content

Gear and Transmission Technology

Gear Geometry - Spur Gears

Damage of gears

Basics of the gear development process I

Basics of the gear development process II

Investigation of gears - Fatigue tests

Investigation of gears - Running behavior

Gear Production

Gear Production – Finishing

Machine Tools for Gear Production

Simulation

Gear Geometry - Bevel Gears

Special Gears, Beveloids





Title ECTS Workload

Duration of


Examination:

Gear and Transmission

Technology

6 0 0

120 (written)

or max. 60

(oral)

Lecture:


Technology

0 2 60 0

Exercise:


Technology

0 2 60 0

Teaching Unit / Examinations: Examination Gear and Transmission Technology

102

Title Examination Gear and Transmission Technology

Sub-title Exa GTT


Connection to the


Teaching Unit / Examinations: Lecture Gear and Transmission Technology

Title Lecture Gear and Transmission Technology

Sub-title L GTT


Connection to the


Teaching Unit / Examinations: Exercise Gear and Transmission Technology

Title Exercise Gear and Transmission Technology

Sub-title E GTT


Connection to the


103

Elective Courses – Third Semester

Practicale Experiences or Elective Courses

Note: Instead of an internship, students may take elective modules in the scope of at least 12 Credit Points.

Module: Internship

Module Internship

Module level Master

Subtitle I


Semester 3



Language English


Elective module

Teaching form Internship report (Examination) (Exa), Internship (I)

Workload Total 12 weeks

Lecture hours -


12


-none-

Learning objectives See guidelines for practical training in the examination regulations

Content See guidelines for practical training in the examination regulations

Media -

Literature -


104

Title ECTS


Examination: Internship

12 0 0 -

Internship: Internship

0 0 360 0

Teaching Unit / Examinations: Examination Internship

Title Examination Internship

Sub-title Exa I

Semester 4


Elective module

105


Language Course

Module: Linguistic Elective

Module Linguistic Elective

Module level Master

Subtitle LE




Lecturer -

Language Freely selectable

Assignment to the





ECTS-Credit Points

(CP) 2

Requirements

according to

examination

regulation

-none-


Title ECTS Workload

Duration of


Examination:

Linguistic Elective 2 0 0

60-90 min.

written

Lecture:

Linguistic Elective 0 1 15 0

Exercise:

Linguistic Elective 0 1 15 0

Teaching Unit / Examinations: Linguistic Elective

106

Title Examination Linguistic Elective

Sub-title Exa LE


Connection to the


Teaching Unit / Examinations: Linguistic Elective

Title Lecture Linguistic Elective

Sub-title L LE


Connection to the


Teaching Unit / Examinations: Exercise Linguistic Elective

Title Exercise Linguistic Elective

Sub-title E LE


Connection to the


107

Compulsory Course – Fourth Semester

Master Thesis

Module: Master Thesis

Module Master Thesis

Module level Master

Subtitle MaTh



Language English


Compulsory module

Workload 6 Months


30


The topic of the Master Thesis cannot be assigned until 85 CP have been successfully completed.

Learning objectives

Master Thesis

The students learn how to independently approach and work on academic topics, document their progress and finalize the entire project within a given deadline. They acquire systematic academic research skills.

Content

Master Thesis

Complete academic paper to show that the students are capable of independently working on a problem related to their subject using academic methods.

networked production engineering (m.sc.)’ · 2020-01-24 · numerical and motion controls of...

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