Digital Manufacturing – Introduction
Digital Manufacturing
Introduction
Winter Semester 2023/2024
Dr. rer. med. Mario Lorenz
Prof. Dr.-Ing. Philipp Klimant
Dr. rer. med. Mario Lorenz 1
Digital Manufacturing – Introduction
Agenda
1 Introduction
1.1 Digital Manufacturing within Advanced Manufacturing
1.2 Introduction of speakers
1.3 Content overview
1.4 Who we are and where we are!
Dr. rer. med. Mario Lorenz 2
Digital Manufacturing – Introduction
Digital Manufacturing within Advanced Manufacturing
Digital Manufacturing…
… is one of four basic modules
… gives a broad overview of modern manufacturing
… introduces main ideas and concepts
… provides the basis for later profile modules
… does not focus on one topic in detail
… has a personal touch: Virtual and Augmented Reality!
Dr. rer. med. Mario Lorenz 3
Digital Manufacturing – Introduction
Agenda
1 Introduction
1.1 Digital Manufacturing within Advanced Manufacturing
1.2 Introduction of speakers
1.3 Content overview
1.4 Who we are and where we are!
Dr. rer. med. Mario Lorenz 4
Digital Manufacturing – Introduction
Introduction of speakers
Dr. rer. med. Mario Lorenz
Contact
Email: [Link]@[Link]
Tel.: +49 (0)371 / 531-39366
University Education
2020 Graduation Doctor of medical sciences (Dr. rer. med.) „Investigation of the relationship between presence and
user experience in virtual reality as a basis for the development of training systems and medical devices in
surgery “, University of Leipzig
2008 – 2010 Master of Science „Computer Science“ at University of Applied Sciences Zwickau
2004 – 2008 Diploma „Computer Science“ at University of Applied Sciences Zwickau
Scientific Career
since 2020 Manufacturing Helix Leader of Open Innovation Netzwork Crowdhelix
since 2020 Visiting scientist Department of Macroscopic and Clinical Anatomy, Medical University of Graz
since 2016 Visiting scientist Department of Orthopedics, Trauma and Plastic Surgery, University Hospital Leipzig
since 01/2011 Research Associate Division Process Informatics and Virtual Product Development, IWP, CUT
Miscellaneous
since 2017 Co-Founder and Head of Project Management of the auvirea GmbH (company in the field of Virtual and
Augmented Reality)
2017 Research visit University of Otago, Dunedin, New Zealand
2015 FRIENZ Study group tour member feciliating EU – New Zealand cooperation
2013 Research visit University of Patras, Patras, Greece
2012 Research visit Norwegian Computing Center, Oslo, Norway
Since 2012 Guest lectures at University of Applied Sciences Zwickau, Karlsruhe Institute of Technology, University of
Otago
Since 2015 Reviewing for Journal of Medical Internet Research, JMIR Research Protocols, IEEE VR, ISMAR, IEEE DIS,
Scientific Reports, IEEE Transactions on Visualization and Computer Graphics, Frontiers in Robotics and AI,
Frontiers in Virtual Reality, PLOS ONE
Dr. rer. med. Mario Lorenz 5
Digital Manufacturing – Introduction
Introduction of speakers
Prof. Dr.-Ing. Philipp Klimant
University Education
2013 Graduation Dr.-Ing. in the field of Process Informatics; Title „Virtual Reality Supported Kinematics and
Material Removal Simulation for Milling Machines using Hardware-in-the-Loop “, TU Chemnitz
2002 – 2007 Diploma „Electrical Engineering – Automation“ at University of Applied Sciences Mittweida
Scientific Career
since 09/2023 Professor for Virtual Technologies at University of Applied Sciences Mittweida
since 02/2019 Division Director, Smart Factory – Digitalization & Automation, Fraunhofer Institute for Machine Tools and
Forming Technology IWU
2019 - 08/2023 Chief Executive Engineer, Professorship for Machine Tool Design and Forming Technology, Institute of
Machine Tools and Production Processes (IWP), Chemnitz University of Technology (CUT)
04 – 12/2018 Chief Engineer Research, Professorship for Machine Tool Design and Forming Technology, IWP, CUT
2017 – 2020 Location Coordinator for the »Saxon Alliance for MAterial- and Resource-Efficient TechnOlogies« (AMARETO),
joint project of TU Bergakademie Freiberg, TU Dresden, TU Chemnitz and Fraunhofer IWU, [Link]
2013 – 2015 Head of the Central Coordination Office of the Cluster of Excellence »Energy-Efficient Product and Process
Innovations in Production Engineering« (eniPROD), CUT and Fraunhofer IWU; [Link]
2011 – 2019 Head of Research Division Process Informatics and Virtual Product Development, IWP, CUT
2007 – 2010 Research Associate, IWP, CUT
Miscellaneous
since 2017 Co-Founder and CEO of the auvirea GmbH (company in the field of Virtual and Augmented Reality)
2011 – 2013 Graduate of the Leadership Academy of the Fraunhofer IWU
2006 – 2007 Diploma Student at Siemens in Chemnitz (development of PLC hardware)
04 – 10/2006 Internship at Veeco Instruments in Santa Barbara, CA, USA (development of SPM microscopes)
02 – 08/2005 Internship and Working Student at Siemens in Chemnitz (development of PLC hardware)
Dr. rer. med. Mario Lorenz 6
Digital Manufacturing – Introduction
Agenda
1 Introduction
1.1 Digital Manufacturing within Advanced Manufacturing
1.2 Introduction of speakers
1.3 Content overview
1.4 Who we are and where we are!
Dr. rer. med. Mario Lorenz 7
Digital Manufacturing – Introduction
Content overview
Main goal of lecture: Overview of digital manufacturing
Main Content:
Machine tools
Computer-aided manufacturing (CAM)
Data acquisition in the context of machine tools and factories
Virtual & augmented reality in machine engineering
Digital factory
Industry 4.0
Dr. rer. med. Mario Lorenz 8
Digital Manufacturing – Introduction
Content overview
Main goal of lecture: Overview of digital manufacturing
Main Content:
Industry 4.0
Internet of things
Digital factory
Data acquisition in the context of machine tools and factories
Dr. rer. med. Mario Lorenz 9
Digital Manufacturing – Introduction
Content overview
2. Digital Factory (2 lectures)
2.1 Definition and overview
2.2 Methods and tools
2.3 Human factors in the digital factory
2.4 Data management
2.5 Application examples of the digital factory
3. Smart manufacturing (2 lectures)
3.1 Introduction
3.2 Theory and technical terms of smart manufacturing
3.3 Planning smart factories
3.4 Smart factory operation with modern technologies
3.5 Introducing new smart manufacturing approaches
3.6 Outlook on upcoming research fields
Dr. rer. med. Mario Lorenz 10
Digital Manufacturing – Introduction
Content overview
4. Data acquisition and data flows in factories (1 lectures)
4.1 General classification
4.2 Production data acquisition
4.3 Machine data acquisition
4.3 Networking of machines tools
4.5 Condition monitoring
4.6 Predictive maintenance
4.7 Digital and virtual twin
Dr. rer. med. Mario Lorenz 11
Digital Manufacturing – Introduction
Content overview
Main goal of lecture: overview of modern manufacturing
Main Content:
Machine tools
Computer-aided technologies (CAD/CAP/CAM)
NC-programming
Dr. rer. med. Mario Lorenz 12
Digital Manufacturing – Introduction
Content overview
5. CAx: Computer-aided technologies (5 lectures)
5.1. Solution framework and basic concepts
5.2. Product model and partial model
5.3. Computer-aided design
5.4. Computer-aided planning and NC-programming
5.5. Manual NC-programming (G-code)
5.6. SFP
5.7. CAM-systems
Dr. rer. med. Mario Lorenz 13
Digital Manufacturing – Introduction
Content overview
Main goal of lecture: overview of modern manufacturing
Main Content:
Virtual Commissioning
Digital Twin
Dr. rer. med. Mario Lorenz 14
Digital Manufacturing – Introduction
Content overview
6. Virtual commissioning (2 lectures)
6.1 Motivation
6.2 Definition
6.3 Variants
6.4 Procedure
6.5 Benefits and issues
6.6 Applications and industrial software
6.7 Practice example: development of an automated guided vehicle
6.8 Practice example: commissioning of NC-programs
Dr. rer. med. Mario Lorenz 15
Digital Manufacturing – Introduction
Content overview
Main goal of lecture: overview of modern manufacturing
Main Content:
Virtual & augmented reality in machine engineering
Dr. rer. med. Mario Lorenz 16
Digital Manufacturing – Introduction
Content overview
7. Virtual and Augmented Reality (2 lectures)
7.1 Virtual Reality
7.2 Augmented Reality
Dr. rer. med. Mario Lorenz 17
Digital Manufacturing – Introduction
Agenda
1 Introduction
1.1 Digital Manufacturing within Advanced Manufacturing
1.2 Introduction of speakers
1.3 Content overview
1.4 Who we are and where we are!
Dr. rer. med. Mario Lorenz 18
Digital Manufacturing – Introduction
Who we are and where we are!
Chemnitz – the City of Modernity
source: [Link] Chemnitz
Kaufhof Galeria
by Helmut Jahn
source: Wikipedia, André Karwath
source: [Link]
Karl Marx monument
Opera house Town Hall Park with Red Tower Downtown
Dr. rer. med. Mario Lorenz 19
Digital Manufacturing – Introduction
Who we are and where we are!
Saxony
source: Gaestehaus [Link]
Sachsen
source: [Link]
source: [Link]
source: Freie Presse
source: Wikipedia, André Karwath source: Stadtgeschichtliches Museum Leipzig
Dr. rer. med. Mario Lorenz 20
Digital Manufacturing – Introduction
Who we are and where we are!
Mechanical Engineering in Saxony
SAXONY-ANHALT
BRANDENBURG
POLAND
THURINGIA
CZECH REPUBLIC
1,000 companies
45,000 employees
BAVARIA
Source picture: Vemas 2020
Dr. rer. med. Mario Lorenz 21
Digital Manufacturing – Introduction
Who we are and where we are!
Saxony – Cradle of Mechanical Engineering in Germany
1846 232 mechanical engineering companies in Saxony (1st position in Germany)
source: G. Spur „Vom Wandel der Industriellen Welt durch Werkzeugmaschinen“
1848 First machine tools construction with process suitable for series production in
Germany by Johann Zimmermann, Chemnitz
Source: [Link]
Johann Zimmermann‘s machine tool factory 1868: View into the production hall,
in Chemnitz Richard Hartmann‘s machine tool factory
Dr. rer. med. Mario Lorenz 22
Digital Manufacturing – Introduction
Who we are and where we are!
Source [NSI19]
Dr. rer. med. Mario Lorenz 23
Digital Manufacturing – Introduction
Who we are and where we are!
Source [NSI19]
Dr. rer. med. Mario Lorenz 24
Digital Manufacturing – Introduction
Who we are and where we are!
Saxony – Cradle of German Automotive Engineering
1904 Horch Werke, Zwickau
(aluminium casting for engines and gearbox cases;
cardan shaft as power transmission element)
1909 Audi Werke in Zwickau
(steering wheel on the left-hand side, centred gear stick)
1932 Horch and Audi Werke merge with source: Horch Museum Zwickau
Wanderer Chemnitz and DKW Zschopau
to Auto Union AG (four rings)
1948-1990 car factory “Sachsenring“, Zwickau
100 YEARS
AUDI
source: Auto Bild
source: [Link]
Dr. rer. med. Mario Lorenz 25
Digital Manufacturing – Introduction
Who we are and where we are!
Saxony – Automotive Engineering today
VW Sachsen GmbH
locations in Mosel,
Chemnitz and Dresden
Quelle: Automobil-Produktion
Porsche
and
BMW
in Leipzig
Quelle: [Link] Quelle: BMW
Dr. rer. med. Mario Lorenz 26
Digital Manufacturing – Introduction
Who we are and where we are!
Chemnitz University of Technology
1836 Foundation of the Royal Mercantile College
1900 Royal Technical Academy
1929 State Academy of Technology
1953 College for Mechanical Engineering
1969 Technical College
1986 University of Technology
8 Faculties with 27 Institutes
Natural Sciences
Mathematics
Mechanical Engineering (1.586 Students)
Electrical Engineering / Information Technology
Computer Science
Economics and Business Administration
Humanities
Behavioural and Social Sciences
Dr. rer. med. Mario Lorenz 27
Digital Manufacturing – Introduction
Who we are and where we are!
Overview: Facts and Figures of the Professorship
Staff Areas of Academic Research and Teaching
1 professor Cutting and Machine Tools
4 associate & honorary professors Control and Feedback Control
50 employees Technology
23 student assistants Process Informatics /
Virtual Product Development
45 doctoral candidates
Dr. rer. med. Mario Lorenz 28
Digital Manufacturing – Introduction
Who we are and where we are!
University Campus
Dr. rer. med. Mario Lorenz 29
Digital Manufacturing – Introduction
Who we are and where we are!
Research under the heading “Resource-Efficient Production“
Founded July 1st 1991
Currently > 600 employees (incl. Students)
40 to 50 million € annual research volume
Locations: Chemnitz (headquarters)
Dresden, Zittau, Wolfsburg, Leipzig
3 scientific fields:
Mechatronics and Forming Technology Machine Tools, Production
Lightweight Structures Systems and Machining
Source [IWU19]
Dr. rer. med. Mario Lorenz 30
Digital Manufacturing – Introduction
Who we are and where we are!
Region Today: E³-Research Factory at Fraunhofer IWU
Next generation of production technique
How we keep production up-to-date?
How we keep production in EU, D, Saxony?
The E³ concept of production
Energy- und Resource efficiency
Emission neutral and energy independent
Embedding of people into production in a new
way
R&D focus in manufacturing
Powertrain components
Body-in-white structures
Energy management “2.0”
Dr. rer. med. Mario Lorenz 31
Digital Manufacturing – Introduction
Who we are and where we are!
IWU Strategy “Resource-Efficient Production“
IWU tackles the E³ issues:
E1: Efficient technology
Holistic approach and near production-oriented realization of process chains
Flexible and intelligent car body construction
Ultra-short process chains for powertrain components
E2: Energy-optimized factory
Integrated energy and material flow management system
Synchronization of energy supply and energy demand
Integration of energy storage systems into production
E3: Embedding humans into production as guarantors of success
Knowledge – learning – working
IC-technology for production (Industry 4.0)
Human-machine interaction
Dr. rer. med. Mario Lorenz 32
Digital Manufacturing – Introduction
Who we are and where we are!
Video ???
Dr. rer. med. Mario Lorenz 33
Digital Manufacturing – Introduction
End of the Lecture
Dr. rer. med. Mario Lorenz 34