micro production

Optical systems are a popular choice for quality inspection because they are not only contactless and precise but also comparably fast. Particularly in cases where a 100% quality inspection is required low measurement and evaluation time is of essential importance. With high production rates of several parts per second, manual inspection is not feasible anymore and the evaluation needs to be automatically carried out by algorithms. In this article we propose a fast method for anomaly detection in image data based on principal component analysis and filtering. The method shows competitive performance on a data set of challenging surface inspection.

Exact planning and configuration of process chains contributes significantly to manufacturing excellence in micro manufacturing. In this type of manufacturing, production must adhere to very low tolerances. Furthermore, a multitude of manufacturing processes is available in micro manufacturing whereas some processes are better suited than others for given tasks. The methodology “Micro Process Planning and Analysis” (µ-ProPlAn), which is described in this article, provides suitable means for planning and configuration of such process chains with the necessary level of detail. To reduce the manual workload in comparing alternative process chains, this article proposes an extension, which enables an automatic selection of alternative processes based on a geometry oriented annotation of the µ-ProPlAn process models.

Due to the increased product miniaturization, a number of new applications and market opportunities open up for mechanical micro-manufacturing. In the manufacturing process with part dimensions less than one millimeter and tolerances in the micrometer range occur so-called “size effects”. These prevent a simple scaling of processes known methods from the macro level and lead to an increased occurrence of quality deviations. In conclusion, the process capability according to ISO 21747 is affected and therefore the application of statistical process control (SPC) is more difficult. In this paper, the interaction between technical and logistical quality objectives in terms of logistical quality control are analyzed at the example of micro cold forming. Thereby, methods of statistical process control and fuzzy control are used.

Due to the increasing miniaturization in all areas, mechanical manufacturing processes of micro-components become more important. The combination of high production cycles and low manu-facturing tolerances in the micrometer range requires a comprehensive quality management, which seeks efficient processes with low quality costs. Because of the small component sizes and the difficulties associated with the handling process, the classic visual inspection retires as testing procedure. In combination with a customized micro-manufacturing surface metrology, an efficient image processing system is needed to identify surface imperfections such as cracks, dents and scratches. This paper presents different standards and applications on the basis of quality management that affect the surface inspection of micro components. By reference to a micro-thermoformed component from the Collaborative Research Centre (CRC) 747, the prototypical implementation of an automated image processing system is ...

The shortening of both time to market und product life cycle in combination with an increase of cost pressure, demand a fast and flexible product development process. The idea of simultaneous engineering is to gain time by treating product, process and resources in parallel and thus discovering discrepancies faster and adjusting the necessary factors. In order to establish an efficient knowledge management a wiki platform, here acting as a social software, is introduced. It serves as a centre of navigation within the process chain and supports the communication between the subprojects. Content can be edited by any member of the research project and may be discussed and changed by others. Its fast and free implementation qualifies the wiki tool and offers a secure and easy to handle platform.

The increasing demand of hybrid micro-technical systems resp. products in small to middle size lots, requires on the one hand new concepts from the micro production engineering and the production process planning and on the other hand methods for the development of micro production systems. Taking the postulation „small machines for small components“ into account, Micro Factories consist of highly specialized mini machines, each having a footprint of about 0,09 m² in comparison to 5 m² of conventional systems [1]. Micro Factories are arranged independently for each task to form a complex production system. Viewing the use of mini machines in micro production from the perspective of the production process, a concept for using adaptive, automatic quality control loops is proposed.

Recent investigations concerning the international state of the art of micro production technology [1, 2] showed, that it has to be distinguished between two main development directions regarding the manufacturing of function units on the one hand as well as complete products on the other hand. First of all there are the classical precision engineering oriented manufacturing methods [3, 4], e.g. according to the DIN 8580 [5]. Secondly manufacturing methods from the area of microsystems technology have been observed [3, 4]. The integration process of different product functions into one part or component geometry, which is running parallel to the miniaturisation, is a specific challenge regarding the field of micro manufacturing [1]. This affects especially the product and production process development, concerning the precision engineering oriented manufacturing methods. This paper addresses problems regarding the operations management of precision-engineering-oriented micro-production ...

Complex production systems in micro production, concerning the manufacturing of miniaturised systems, assemblies and components, are very special. For example Hesselbach [1] stated, that micro production technology (sometimes to be found as (ultra) precision engineering) spans basically all, partly highly specialised production techniques. Kiesewetter [2] points out, that micro production is not just a kind of “shrinked machine building or mechanical engineering”. Mostly the whole manufacturing process chain or at least larger, interrelated section or subsystems and -processes, for example mainly for the manufacturing of miniaturised mechanical modules or assemblies respectively, are basically not examined. The paper discusses and presents topics concerning the planning and operations of micro production manufacturing process chains, against the background of the manufacturing of miniaturised mechanical modules and components.