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In the course of the last few years, our students are becoming increasingly unhappy. Sometimes they stop attending lectures and even seem not to know how to behave correctly. It feels like they are getting on strike. Consequently, drop-out rates are sky-rocketing. The lecturers/professors are not happy either, adopting an “I-don’t-care” attitude.
An interdisciplinary, international team set in to find out: (1) What are the students unhappy about? Why is it becoming so difficult for them to cope? (2) What does the “I-don’t-care” attitude of professors actually mean? What do they care or not care about? (3) How far do the views of the parties correlate? Could some kind of mutual understanding be achieved?
The findings indicate that, at least at our universities, there is rather a long way to go from “Engineering versus Pedagogy” to “Engineering Pedagogy”.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
One of the challenges in humanoid robotics is motion control. Interacting with humans requires impedance control algorithms, as well as tackling the problem of the closed kinematic chains which occur when both feet touch the ground. However, pure impedance control for totally autonomous robots is difficult to realize, as this algorithm needs very precise sensors for force and speed of the actuated parts, as well as very high sampling rates for the controller input signals. Both requirements lead to a complex and heavy weight design, which makes up for heavy machines unusable in RoboCup Soccer competitions.
A lightweight motor controller was developed that can be used for admittance and impedance control as well as for model predictive control algorithms to further improve the gait of the robot.
There are additional long-term effects which also change the micro-structure of the polymer network and consequently the effective number of polymer chains in the material. These effects are summarized by ageing processes and will be used in the following to explain the basic assumptions of the model which can be generalized to simulate the viscous behaviour of the material. An implementation of these concepts into FEM codes is straightforward and has been carried out to the solver ABAQUS, Baaser & Ziegler (2006), Baaser et al. (2009).
Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material’s yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests.
Thin-layer chromatography is a rapid and reliable working method for quantification of mycotoxins which is suitable for checking EC legislation aflatoxin limits for dried figs without an RP-18 pre-column cleaning step. We describe normal-phase chromatography on silica gel plates with 2.4:0.05:0.1:0.05 ( v/v ) methyl t -butyl ether-water-methanol-cyclohexane as mobile phase and reversed-phase chromatography on RP-18 plates with methanol-4% aqueous ZnSO 4 solution-ethyl methyl ketone 15:15:3 ( v/v ) as mobile phase. Sample pretreatment was by modified QuEChERS (Quick, Easy, Cheap, Effective, Rugged, Safe) extraction with tetrahydrofuran or acetone. NaCl was used as QuEChERS salt. Response was a linear function of amount chromatographed in the ranges 3 to 100 pg per zone for aflatoxins B 2 and G 2 , 10 to 350 pg per zone for the aflatoxins B 1 and G 1 , and 0.25 to 2.5 ng per zone for ochratoxin A. Quantification limits for the aflatoxins were between 13 and 35 pg per zone (equivalent to 1.5 and 2.4 ppb, taking the pre-treatment procedure into account). Ochratoxin A was detectable with a limit of quantification of 970 pg per zone, corresponding to 56 ppb in the sample. Normal phase and RP-18 separations work rapidly, reliably, and at low cost. They are also suitable for checking the content of the mycotoxins patulin, penicillic acid, zearalenone, and deoxynivalenol.
Most recently, the federal government in Germany published new climate goals in order reach climate neutrality by 2045. This paper demonstrates a path to a cost optimal energy supply system for the German power grid until the year 2050. With special regard to regionality, the system is based on yearly myopic optimization with the required energy system transformation measures and the associated system costs. The results point out, that energy storage systems (ESS) are fundamental for renewables integration in order to have a feasible energy transition. Moreover, the investment in storage technologies increased the usage of the solar and wind technologies. Solar energy investments were highly accompanied with the installation of short-term battery storage. Longer-term storage technologies, such as H2, were accompanied with high installations of wind technologies. The results pointed out that hydrogen investments are expected to overrule short-term batteries if their cost continues to decrease sharply. Moreover, with a strong presence of ESS in the energy system, biomass energy is expected to be completely ruled out from the energy mix. With the current emission reduction strategy and without a strong presence of large scale ESS into the system, it is unlikely that the Paris agreement 2° C target by 2050 will be achieved, let alone the 1.5° C.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.
Process engineering focuses on the design, operation, control and optimization of chemical, physical and biological processes and has applications in many industries. Process Intensification is the key development approach in the modern process engineering. The proposed Advanced Innovation Design Approach (AIDA) combines the holistic innovation process with the systematic analytical and problem solving tools of the theory of inventive problem solving TRIZ. The present paper conceptualizes the AIDA application in the field of process engineering and especially in combination with the Process Intensification. It defines the AIDA innovation algorithm for process engineering and describes process mapping, problem ranking, and concept design techniques. The approach has been validated in several industrial case studies. The presented research work is a part of the European project “Intensified by Design® platform for the intensification of processes involving solids handling”.
Alexander von Humboldt, a German scientist and explorer of the 19th century, viewed the natural world holistically and described the harmony of nature among the diversity of the physical world as a conjoining between all physical disciplines. He noted in his diary: “Everything is interconnectedness.”
The main feature of Humboldt’s pioneering work was later named “Humboldtian science”, meaning the accurate study of interconnected real phenomena in order to find a definite law and a dynamic cause.
Following Humboldt's idea of nature, an Internet edition of his works must preserve the author’s original intention, retain an awareness of all relevant works, and still adhere to the requirements of scholarly edition.
At the present time, however, the highly unconventional form of his publications has undermined the awareness and a comprehensive study of Humboldt’s works.
Digital libraries should supply dynamic links to sources, maps, images, graphs and relevant texts. New forms of interaction and synthesis between humanistic texts and scientific observation need to be created.
Information technology is the only way to do justice to the broad range of visions, descriptions and the idea of nature of Humboldt’s legacy. It finally leads to virtual research environments as an adequate concept to redesign our digital archives, not only for Humboldt’s documents, but for all interconnected data.
The authors present an abiotically catalyzed glucose fuel cell and demonstrate its application as energy harvesting power source for a cardiac pacemaker. This is enabled by an optimized DC-DC converter operating at 40 % conversion efficiency, which surpasses commercial low-power DC-DC converters. The required fuel cell surface area can thus be reduced from about 125 cm2 to 18 cm2, which would allow for its direct integration onto the pacemaker casing.
Today, thermoforming moulds are mostly produced using conventional mould-building technologies (e.g. milling and drilling) and are made of metal (e.g. aluminium or steel) or hardwood. The tools thus produced are very robust, but are only cost-effective in mass production. For the production of small batches of thermoformed parts, there is a need for moulds which can be produced quickly and economically. A new approach which significantly reduces the production time and cost is the 3D printing process (3DP). The use of this technology to produce thermoforming moulds offers many new options in the geometries which can be manufactured, and in manufacturing time and costs. In a case study of a thermoformed part (a scaled automotive model), the pre-processing of the CAD model of a mould is demonstrated. The mould can be printed within a few hours, and is sufficiently heat-resistant for moulding processes. The important advantages of moulds printed in 3D, in comparison to moulds built using conventional technologies, are the ability to create any shape of channels for the vacuum and the simplification in the production of tool mock-ups. This paper also discusses the economics of the technique, such as a comparison of material costs and manufacturing costs in relation to conventional production technologies and materials.
Cast aluminum cylinder blocks are frequently used in gasoline and diesel internal combustion engines because of their light-weight advantage. However, the disadvantage of aluminum alloys is their relatively low strength and fatigue resistance which make aluminum blocks prone to fatigue cracking. Engine blocks must withstand a combination of low-cycle fatigue (LCF) thermal loads and high-cycle fatigue (HCF) combustion and dynamic loads. Reliable computational methods are needed that allow for accurate fatigue assessment of cylinder blocks under this combined loading. In several publications, the mechanism-based thermomechanical fatigue (TMF) damage model DTMF describing the growth of short fatigue cracks has been extended to include the effect of both LCF thermal loads and superimposed HCF loadings. This approach is applied to the finite life fatigue assessment of an aluminum cylinder block. The required material properties related to LCF are determined from uniaxial LCF tests. The additional material properties required for the assessment of superimposed HCF are obtained from the literature for similar materials. The predictions of the model agree well with engine dyno test results. Finally, some improvements to the current process are discussed.
4D printing (4DP) is an evolutionary step of 3D printing, which includes the fourth dimension, in this case the time. In different time steps the printed structure shows different shapes, influenced by external stimuli like light, temperature, pH value, electric or magnetic field. The advantage of 4DP is the solution of technical problems without the need for complex internal energy supply via cables or pipes. Previous approaches to 4D printing with magnetoresponsive materials only use materials with limited usability (e.g. hydrogels) and complex programming during the manufacturing process (e.g. using magnets on the nozzle). The 4D printing using unmagnetized particles and the later magnetization allows the use of a standard 3D printer and has the advantage of being easily reproducible and relatively inexpensive for further application. Therefore, a magnetoresponsive feedstock filament is produced which shows elastic and magnetic properties. In a first step, pellets are produced by compounding polymer with magnetic particles. In a second step, those pellets are extruded in form of filament. This filament is printed using a conventional printing system for Material Extrusion (MEX-TRB/P). Various prototypes have been printed, deformed and magnetized, which is called programming. In comparison to shape memory polymers (SMP) the repeatability of the movement is better. The results show the possibilities of application and function of magnetoresponsive materials. In addition, an understanding of the behaviour of this novel material is achieved.
More than 200 years ago, the scientist Alexander von Humboldt noted in his travel diaries that "everything is interconnectedness", when he was fascinated by nature and the phenomena observed. The view of nature has become much more detailed through the knowledge of phenomena and natural processes, which led to a more precise view of nature shaped by Humboldt. Technological progress and the artificial intelligence of highly developed computer systems are upsetting this view and changing the established world view through a new, unprecedented interaction between man and machinery. Thus we need digital axioms and comprehensive rules and laws for such autonomous acting systems that determine human interaction between cybernetic systems and biological individuals. This digital humanism should encompass our relationship to nature, our handling of the complexity and diversity of nature and the technological influences on society in order to avoid technical colonialism through supercomputers.
To improve the building’s energy efficiency many parameters should be assessed considering the building envelope, energy loads, occupation, and HVAC systems. Fenestration is among the most important variables impacting residential building indoor temperatures. So, it is crucial to use the most optimal energy-efficient window glazing in buildings to reduce energy consumption and at the same time provide visual daylight comfort and thermal comfort. Many studies have focused on the improvement of building energy efficiency focusing on the building envelope or the heating, ventilation, and cooling systems. But just a few studies have focused on studying the effect of glazing on building energy consumption. Thus, this paper aims to study the influence of different glazing types on the building’s heating and cooling energy consumption. A real case study building located under a semi-arid climate was used. The building energy model has been conducted using the OpenStudio simulation engine. Building indoor temperature was calibrated using ASHRAE’s statistical indices. Then a comparative analysis was conducted using seven different types of windows including single, double, and triple glazing filled with air and argon. Tripleglazed and double-glazed windows with argon space offer 37% and 32% of annual energy savings. It should be stressed that the methodology developed in this paper could be useful for further studies to improve building energy efficiency using optimal window glazing.