Aiming the rapid response of mega constellation of satellites to cover the increasing demand for Earth observation and communication, in-orbit manufacturing is a promising approach. Driven by the NewSpace, which is leading a paradigm change in the space industry, the project Space Factory 4.0 has been founded to establish new processes and technologies based on the Industrie 4.0 approaches for rapid satellite assembly on an in-orbit platform. One of its fundamental approaches and the main contribution of this paper is the Digital Twins. In the scope of a Space Factory 4.0, the Digital Twin is a holistic approach for supporting and controlling systems for in-orbit Assembly, Integration, and Test processes, as well as satellite operations, by establishing a bidirectional link to its physical counterpart. It is an essential approach to obtain a digital representation of the current state of the real product at any time, enabling the recognition of and reaction to disruptive parameters at an early stage. To model Digital Twins and to meet the specific requirements of a Space Factory 4.0, such as the capability of sending telecommands and processing telemetry data, an extension of Industrie 4.0 component, called Space Factory 4.0 component, is proposed. This paper discusses this concept, its implementation and the results obtained and concludes to discuss its benefits and potentials for the space industry.
With the help of new design tools, manufacturing‐integrated solutions can be generated that concurrently consider function and process. Based on the design pattern matrix, solution elements can be developed that realize the product function by systematically utilizing manufacturing‐induced properties. The developed manufacturing‐integrated product solutions are refined using computer‐aided methods (feature‐based modeling and information modeling). A product embodiment is generated that is specifically tailored to the chosen manufacturing technology. An integrated information model allows the introduced tools to be used throughout the entire development process. The example of a linear flow split snap‐fit fastening illustrates how the tools beneficially interact and realize manufacturing potential, resulting in an innovative product design.
Daylighting not only provides alternative illumination to artificial lighting that can reduce energy consumption, it also can increase an inhabitant's productivity and help to relieve depression. Maximizing the access of daylight for an interior space in a dense urban environment has thus become a priority in lighting design. Digital lighting simulation using high dynamic range imaging for image-based lighting can provide accurate daylight simulation of an interior luminance distribution. However, the method of generating a high-dynamic range light probe image is limited to the setting of a flat landscape with an unobstructed view. This paper presents an innovative system that is implemented using a lightweight smartphone camera equipped with a fish-eye lens on a customized unmanned aerial vehicle (UAV). The system can be remotely controlled to loiter, recording multiple images in a horizontal direction. The captured images can then be assembled into a high dynamic range light probe image to be used as the image-based lighting source for interior spaces with onedirectional access to daylight. The pilot test proved that the light probe images generated with the constructed prototype and system provide reasonable accuracy in daylight simulation.
The Collaborative Research Centre 666 has the focus on researching fundamental new methods for the development of optimized products and production processes for integral bifurcated sheet metal parts. Technological innovations have been achieved with respect to new production processes such as linear flow splitting and linear bend splitting as well as to produce products with flexible profiles. The use of state of art product development methodologies can be applied but these are not optimized to deal with the high complexity of the requirements and properties of integral bifurcated sheet metal products. In order to deal with that complexity a new approach of a product development methodology, the algorithm based product development process, has been established. Within the scope of the algorithm based product development methodology a topology optimization, based on mathematical algorithms using product requirements information, is already applied in the conceptual steps of product development process. By using this methodological approach an optimized concept of bifurcated sheet metal can be determined. The results are stored as optimized geometric data in XML-format files. 3D-CAD-Models are generated based on these data. However the import of these data into 3D-CAD-Systems are not fully automated. The developed data model, from earlier works for linear flow splitting and linear bend splitting, does not take into account the variability of the profiles in the third-dimension. In addition the topology optimization does not provide production-orientated design requirements and therefore it does not take into account the production process limits (of linear flow splitting and linear bend splitting). Hence 3D-CAD-Models resulting from the optimized geometric data need to be adapted manually. Therefore new advanced approaches in terms of virtual product development tools need to be explored. This paper describes the development of an interface within the CAD-System Siemens NX which supports the automatic import of XML-files containing the optimized geometric data of non-linear integral bifurcated sheet metal in 3D-CAD-Models. The existing data model is extended considering the requirements of the developed interface in order to represent nonlinear bifurcated profiles. An approach of the interface using the described data model and the NX Open API is introduced and explained.
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