A constante evolução de métodos, tecnologias e ferramentas associadas na área de projeto fornece maior capacidade para o projetista. Entretanto, ela também aumenta os requisitos de interfaces e controle do conjunto de componentes de projeto consideravelmente. Tipicamente, este aspecto está presente na área de Projeto Orientado para a Manufatura (DFM) onde existem diversos distintos componentes. Cada um dos componentes existentes, ou futuros, pode ter foco diferente, consequentemente com requisitos de informação, utilização e execução distintos. Este trabalho propõe a utilização de padrões conceituais flexíveis de informação e controle de forma abrangente em uma arquitetura de Projeto Orientado para a Manufatura (DFM). O objetivo principal é auxiliar a análise e resolução de DFM, bem como dar suporte à atividade de projeto estruturando e propondo uma solução em relevantes aspectos em DFM: estruturação do contexto das informações (ou conhecimento) em DFM. A arquitetura utiliza as seguintes atividades de projeto em processos de usinagem: Tolerância, Custo, Acessibilidade da ferramenta, Disponibilidade de máquinas e ferramentas e Análise de materiais para demonstrar a relevância da correta contextualização e utilização da informação no domínio DFM . Sob forma geral, concomitantemente, as amplas necessidades de compreensão dos distintos tipos e formas da informação em DFM demandam que uma arquitetura de projeto tenha capacidade de gerenciar/administrar diferentes contextos de informações de projeto. Este é um tópico relevante tendo em vista que existem diferentes atividades DFM que eventualmente devem ser incluídas no ato de projetar. Tipicamente, cada uma delas tem requisitos distintos em termos de dados e conhecimento, ou contextualização do projeto, que idealmente poderiam ser gerenciados através da arquitetura de informação atual – STEP.Aarquitetura proposta gerencia contextos de informações de projeto através de ontologias direcionadas no domínio DFM. Através dela, será possível compreender e utilizar melhor as intrínsecas interfaces existentes nas informações deste domínio, além de, através disto, aumentar a flexibilidade e eficácia de sistemas DFM. / This work proposes the use of industry standards to support the utilization of Design for Manufacturing (DFM) techniques in a comprehensive scale in the design field. The specific aspect being considered in an architecture is the definition and structure of DFM information context. In order to demonstrate the research concepts, some design activities are implemented the framework (which is focused in machining processes): Tolerancing model, Cost model based on material remove processes, Tool Accessibility model taking into consideration the part being designed, Availability of Machines and Tools model, and Material analysis. The broad needs of design–based frameworks, in general, require that its architecture must have the capabilities to handle di erent framework design information utilization contexts, or information context concepts. This is a relevant aspect since there are severalDFMcomponents/activities that preferably should be included in the design process. Traditionally, each one of them might have distinct data & knowledge requirements, which can be handled by the current information architecture – STEP – only in part. Additionally, each one of them might have, or need, di erent forms of understanding DFM information (information context). The framework handles information context concepts through the use of the ontologies targeted to the DFMfield. It is expected that a better comprehension and usage of the intrinsic information interfaces existent in its domain be achieved. Through it, more flexible and e ective DFM systems information-wise can be obtained.

This thesis deals with the development of novel haptic array system that can render distributed pressure pattern. The haptic devices are force feedback interfaces, which are widely seen from consumer products to tele-surgical systems, such as vibration feedback in game console, mobile phones, virtual reality applications, and daVinci robots in minimally invasive surgery. Telemedicine and computer-enabled medical training system are modern medical infrastructures where the former provides health care services to people especially in rural and remote places while the latter is meant for training the next generation of doctors and medical students. In telemedicine, a patient at a remote location consults the physician at a distant place through the telecommunication media whereas in computer enabled medical training system, physician and medical students interact with the virtual patient. The experience of physical presence of the remote patient in telemedicine and immersive interaction with virtual patient on the computer-enabled training system can be attained through haptic devices. In this work we focus on palpation simulation in telemedicine and medical training systems. Palpation is a primary diagnostic method which involves multi-finger, multi-contact interaction between the patient and physician. During palpation, a distributed pressure pattern rather than point load is perceived by the physician. The commercially available haptic devices are single and five point devices, which lack the face validity in rendering distributed pressure pattern; there are only a few works reported in literatures that deal with palpation simulation. There is a strong need of a haptic device which provide distributed force pattern with multipoint feedback which can be applied for palpation simulation in telemedicine and medical training purposes. The haptic device should be a multipoint device to simulate palpation process, an array device to render distributed force pattern, light weight to move from one place to another and finally it has to cover hand portion of physician. We are proposing a novel under-actuated haptic array device, called taut cable haptic array system (TCHAS), which in general is a m x n system, consist of m+n actuators to obtain m.nhaptels, that are multiple end effectors. A prototype of 3 x 3 TCHAS is developed during this work and detailed study on its characterisation is explored. The performance of device is validated with elaborate user study and it establishes that the device has promising capability in rendering distributed spatio-temporal pressure pattern.

A constante evolução de métodos, tecnologias e ferramentas associadas na área de projeto fornece maior capacidade para o projetista. Entretanto, ela também aumenta os requisitos de interfaces e controle do conjunto de componentes de projeto consideravelmente. Tipicamente, este aspecto está presente na área de Projeto Orientado para a Manufatura (DFM) onde existem diversos distintos componentes. Cada um dos componentes existentes, ou futuros, pode ter foco diferente, consequentemente com requisitos de informação, utilização e execução distintos. Este trabalho propõe a utilização de padrões conceituais flexíveis de informação e controle de forma abrangente em uma arquitetura de Projeto Orientado para a Manufatura (DFM). O objetivo principal é auxiliar a análise e resolução de DFM, bem como dar suporte à atividade de projeto estruturando e propondo uma solução em relevantes aspectos em DFM: estruturação do contexto das informações (ou conhecimento) em DFM. A arquitetura utiliza as seguintes atividades de projeto em processos de usinagem: Tolerância, Custo, Acessibilidade da ferramenta, Disponibilidade de máquinas e ferramentas e Análise de materiais para demonstrar a relevância da correta contextualização e utilização da informação no domínio DFM . Sob forma geral, concomitantemente, as amplas necessidades de compreensão dos distintos tipos e formas da informação em DFM demandam que uma arquitetura de projeto tenha capacidade de gerenciar/administrar diferentes contextos de informações de projeto. Este é um tópico relevante tendo em vista que existem diferentes atividades DFM que eventualmente devem ser incluídas no ato de projetar. Tipicamente, cada uma delas tem requisitos distintos em termos de dados e conhecimento, ou contextualização do projeto, que idealmente poderiam ser gerenciados através da arquitetura de informação atual – STEP.Aarquitetura proposta gerencia contextos de informações de projeto através de ontologias direcionadas no domínio DFM. Através dela, será possível compreender e utilizar melhor as intrínsecas interfaces existentes nas informações deste domínio, além de, através disto, aumentar a flexibilidade e eficácia de sistemas DFM. / This work proposes the use of industry standards to support the utilization of Design for Manufacturing (DFM) techniques in a comprehensive scale in the design field. The specific aspect being considered in an architecture is the definition and structure of DFM information context. In order to demonstrate the research concepts, some design activities are implemented the framework (which is focused in machining processes): Tolerancing model, Cost model based on material remove processes, Tool Accessibility model taking into consideration the part being designed, Availability of Machines and Tools model, and Material analysis. The broad needs of design–based frameworks, in general, require that its architecture must have the capabilities to handle di erent framework design information utilization contexts, or information context concepts. This is a relevant aspect since there are severalDFMcomponents/activities that preferably should be included in the design process. Traditionally, each one of them might have distinct data & knowledge requirements, which can be handled by the current information architecture – STEP – only in part. Additionally, each one of them might have, or need, di erent forms of understanding DFM information (information context). The framework handles information context concepts through the use of the ontologies targeted to the DFMfield. It is expected that a better comprehension and usage of the intrinsic information interfaces existent in its domain be achieved. Through it, more flexible and e ective DFM systems information-wise can be obtained.

This work deals with addressing the issues related to design of double toggle switch mechanisms with emphasis on structural, dimensional and dynamic aspects. Currently, almost all the issues related to electrical switches are dealt from electromagnetic point of view; the operating mechanism is hardly touched. It is observed that kinematic parameters influence electrical performance of switch significantly. Therefore, there is a need to develop methodologies for supporting exploration of diverse kinematic chains (KCs) for this purpose. Visual inspection is tedious and error prone even when a complete list of design criteria is available, hence, the work presented in the thesis contributes towards automated design of toggle switch mechanisms. In this context, in house modular kinematics data structure is found useful for using it as a tool in the design of toggle switch. Modular kinematics, typically used for kinematic analysis, works on the principle of finding the configuration of a mechanism using a given set of modules by a procedure called module sequence. This module sequence is used and interpreted in a number of ways for its effective use in various design stages. Structurally, a set of seven conditions must be satisfied by a KC to exhibit double toggle. These conditions are broadly classified into three categories: criteria for KC, function assignment criteria and criteria for stoppers. These three criteria are to be checked automatically by use of module sequence in the same order as mentioned. In the criteria for KC, one of the conditions is that, the KC should not have fractionated degrees of freedom (d.o.f.). Hence, detection of fractionation in a KC is inevitable. In literature, is was found that the algorithms for detection operate at their worst case complexity, O(n4), and some of them do not report joint fractionation. Thus, the algorithms are not only robust but also computationally expensive. Therefore, a frugal and comprehensive method O(n2) is implemented to detect fractionation using modular kinematics. Also, inherent structural pattern embedded in fractionated KCs is hardly studied in literature. It is found that the way body and joint fractionation is defined in fractionated KCs is inconsistent. So, fractionation is interpreted as symbolic partitioning of joints and links in the traditional body and joint fractionation types respectively. Based on the number of ways of partitioning, simple and multiple types of fractionation are recognized. Valid partitions are identified using the notion of fractionating and non-fractionating subchains. Relative locations of these subchains influence distribution of d.o.f. across the fractionated KC. Conventional representation of KCs as links and joints or graphs is difficult to comprehend this distribution. For this, a novel concept of fractionation graph is introduced that gives d.o.f. distribution information and the relative locations of the constituent subchains across the KC. Modular kinematics gives a constructive description of fractionated KCs. Characterization of fractionated KCs, based on presence of multiple separation links, is introduced as order of fractionation. Uniqueness for a given order of fractionation is also justified. After the criteria for KC, a KC is tested for feasibility for function assignment criteria. This requires recognition of active and passive subchains of the KC with respect to input and output pairs. For this, module sequence is characterized for recognition of the subchains. Based on these subchains, locations of stoppers are derived. Using this information, an algorithmic approach to assign functions (functions like spring, ground link, input link, etc.) to derive distinct driving mechanisms provided isomorphic elements (links and joints) of the KC are known beforehand, is introduced. The design parameters influencing dimensional synthesis have been identified as dimensions of links, spring anchor points and stopper locations. Sub-problems associated with each parameter are analyzed. It is found out that optimum location of stoppers for selecting operational range of motion is necessary by taking into account the considerations of timing of switch and impact velocity. Based on the analysis, an algorithmic way to design single toggle switch mechanisms is introduced. Timing for closing or opening of a switch is one of the critical measure that determines its performance. Timing should be as low as possible without exceeding the impact velocity at the instant contacts meet each other. Timing of a switch depends on the dimensions of the links, inertial parameters, spring stiffness etc. For a given timing for a mechanism, dynamic synthesis, in this thesis, deals with finding the inertial parameters of the links using Quinn's energy distribution method, modular kinematics, and Nelder and Mead's downhill simplex method for optimization. This thesis helps the designer to use modular kinematics as a potential automated tool to select a valid design to make the solution space more meaningful in the design of toggle switch mechanisms.

Triangle meshes have become an increasingly popular shape representation. Given the ease of standardization it allows and the proliferation of devices (scanners, range images ) that capture and output shape information as meshes, this representation is now used in applications such as virtual reality, medical imaging, rapid prototyping, digital art and entertainment, simulation and analysis, product design and development. In product development manipulation of mesh models is required in applications such as visualization, analysis, simulation and rapid prototyping. The nature of manipulation of the mesh includes annotation, interactive viewing, slicing, re-meshing, mesh optimization, mesh segmentation, simplification and editing. Of these editing has received the least attention. Mesh model often requires editing either locally or globally based on the application. With the increased use of meshes it is desirable to have formal reasoning tools that enable manipulation of mesh models in product development. The mesh model may contain artifacts like self-intersection, overlapping triangles, inconsistent normal’s of triangles and gaps or holes with or without islands. It is necessary to repair the mesh before further processing the mesh model. An automatic algorithm is proposed to repair and fill arbitrary holes while maintaining curvature continuity across the boundaries of the hole. The algorithm uses slices across the hole to first identify curves that bridge the hole. These curves are then used to find the surface patch that would fill the hole. The proposed algorithm works for arbitrary holes in any mesh model irrespective of the type of underlying surface and is able to preserve features in the mesh model that are missing in the input information. Since editing during product development is mostly feature based, an automatic algorithm to recognize shape features by directly clustering the triangles constituting a feature in a mesh model is proposed. Shape features addressed in the thesis are volumetric features that are associated with either addition or removal of a finite volume. The algorithm involves two steps – isolating features in 2D slices followed by a 3D traversal to cluster all the triangles in the feature. Editing a mesh model mainly implies editing local volumetric features in that model. An automatic algorithm is proposed for parametric editing of volumetric features in the mesh model. The proposed algorithm eliminates the need of original CAD model while manipulating any volumetric feature in the mesh model based on feature parameters. An automatic algorithm to manipulate global shape parameters of the object using the mesh model is developed. Global shape parameters include thickness, drafts and axes of symmetry. As the mesh models do not explicitly carry this information global editing of mesh models (other than for visualization) has not been attempted thus far. This thesis proposes the use of mid-surface to identify and manipulate global shape parameters for a class of objects that are classified as thin walled objects. Mid-curves are first identified on slices of the part and then the mid-surface is obtained from these mid-curves. Results of implementation are presented and discussed along with the scope for future work.

L’intégration des contraintes d’industrialisation, des pièces en matériaux composites, en conception préliminaire, est un enjeu majeur de la compétitivité des entreprises, et s’inscrit dans une démarche de développement durable. Un travail de captation et de mise en forme de la connaissance industrielle a permis de développer une stratégie d’optimisation. Cette stratégie repose sur une approche multi-métiers, elle permet d’estimer la performance technique et économique d’une solution d’industrialisation. L’estimation de la performance est basée sur l’évaluation, pour chaque solution d’industrialisation, du risque de rupture du composant assemblé, du niveau d’intégration fonctionnelle et du coût de fabrication. La définition de la meilleure alternative est obtenue par la comparaison de la performance de solutions et s’appuie sur des méthodes et outils d’aide à la décision. Le risque de rupture est estimé à partir des écarts entre des caractéristiques de la pièce fabriquée par procédé Resin Transfer Molding (RTM) et les caractéristiques nominales. Les caractéristiques de la pièce fabriquée prises en compte sont : - les écarts géométriques, - les écarts de caractéristiques mécaniques. Dans l’industrie aéronautique, certaines pièces de structure en matériaux composites sont réalisées par le procédé RTM. Dans ce type de mise en forme, les caractéristiques mécaniques du composant sont directement liées au niveau d’imprégnation de la préforme. Dans le travail de thèse, les défauts d’imprégnation sont identifiés comme des écarts volumiques d’imprégnation. Ces écarts ont pour conséquence d’altérer les propriétés mécaniques du matériau qui constitue la pièce. L’estimation des écarts volumiques d’imprégnation est obtenue à partir de l’analyse des résultats de la simulation par éléments finis de l’écoulement de résine dans le renfort fibreux (logiciel Pam RTM®). La géométrie de la pièce obtenue par procédé RTM diffère de la géométrie nominale, cet écart est due en partie aux différences entre les caractéristiques physiques des constituants du matériau composite. Les variations géométriques de la pièce fabriquée sont identifiées comme des écarts géométriques de fabrication. Les écarts géométriques sont compensés, lors de la phase d’assemblage, par des déformations garantissant les contacts avec les pièces adjacentes. Ces déformations génèrent un état de contraintes mécaniques au sein de la pièce. La quantification de l’état de contraintes mécaniques est obtenue à partir d’une simulation thermomécanique par éléments finis réalisée par le logiciel Samcef®. L’aide à la décision est basée sur l’étude combinée de l’état de contraintes mécaniques due à la compensation des écarts géométriques et de l’incidence des écarts volumiques d’imprégnation sur les propriétés mécaniques de la pièce. Trois critères permettent d’estimer le risque de rupture du composant assemblé : un critère de rupture des matériaux composites quantifie le risque de rupture, les deux autres critères, prenant en compte les défauts d’imprégnation, majorent le risque de rupture. Afin de faciliter l’interprétation des résultats et la phase de comparaison de solutions, le risque de rupture est présenté sous forme d’une cartographie. En fonction des couplages des valeurs des critères, une optimisation de la conception et/ou de l’industrialisation est proposée. Une évaluation du niveau d’intégration fonctionnelle ainsi que du coût de fabrication complète la démarche d’aide à la décision. / Integrating industrialization constraints of composite materials into preliminary design is a major challenge for companies in terms of competitiveness, and is part of a sustainable development approach. Work on capturing and formatting industry knowledge has helped develop a design optimization strategy. This strategy is based on multidisciplinary rules, and estimates the technical and economic performance of an industrialization solution. This estimate is based on the evaluation of failure risk of component assembly, level of functional integration and manufacturing cost. The definition of the best alternative is obtained by comparing solution performances, relying on decision support methods and tools. The failure risk is estimated from differences between the characteristics of the part manufactured by Resin Transfer Molding Process (RTM) and the nominal part (CAD). The following characteristics of the manufactured part are taken into account: ? - geometric deviations, ? - characteristic mechanical deviations. In the aviation industry, some structural composite parts are manufacture by RTM. In this type of manufacture, the mechanical properties of the component are directly related to the level of preform impregnation. In this thesis, the impregnation defects are identified as volumic impregnation deviations. These deviations have the effect of altering the mechanical properties of material. Estimated volume impregnation deviations are obtained by analysing the results of the finite element simulation of resin flow into the fibrous reinforcement (software Pam RTM ®). The part geometry obtained using the RTM process differs from the nominal geometry, with the deviation due partly to differences between the physical components of the composite material. The geometric variations in the manufactured part are identified as geometric manufacturing deviations. These geometric deviations are offset, in the assembly phase, by deformations due to contact with adjacent parts, which generate a state of mechanical stress within the part. The mechanical stress state is quantified from a finite element thermomechanical simulation carried out using the Samcef ® software. Decision support is based on the combined study of the state of mechanical stress due to the compensation of geometric deviations and the incidence of volume impregnation deviations on the mechanical properties of the part. Three criteria are used to estimate the failure risk of the assembled component: a composite materials failure criterion quantifies failure risk; the other two criteria, taking into account the impregnation defects, increase the failure risk. To facilitate interpretation of results and the solution comparison phase, the failure risk is represented by mapping. Depending on the coupling values of the criteria, optimizing the design and/or industrialization is proposed. An evaluation of the level of functional integration and manufacturing cost complete the decision support process.

Manual assembly workers have nowadays a much higher workload than before. Not only do they have to deal with many more product variants, but as aconsequence they also receive many more information signals that they have to act upon. This study focuses on the information assembly workers receive through visual instructions. By conducting a literature review in the domains of product development with focus on design for assembly, cognition related to informationin instructions and different instruction formats like paper, tablet, and augmented reality (AR), commonalities and differences could be identified. Assembly operations are generally divided in handling a part and joining a part, and instructions should inform the assembly worker about when what should be assembled where and how. Each of these aspects has an impact on the overall complexity of the assembly process. To realise which of these aspects is most critical for an assembly worker can be of help in creating and delivering effective, tailor made instructions. The main finding is that there is not a one size fits all solution when it comes to the effectiveness of instructions, but that the type of instructions and the way they are delivered should in the first place be adjusted to the complexity of the assembly operations and secondly - if possible - also adjusted to the experience of the worker. The outcomes mentioned in this document should help laying the foundation for rules and guidelines when it comes to manual assembly instructions and its factors to consider.

Bewehrter Beton ist das heutzutage am meisten verwendete Baumaterial. Es ist universell und preiswert nahezu überall auf der Welt herstellbar. Damit einhergehen allerdings ein hoher CO2-Ausstoß und ein beträchtlicher Verbrauch an natürlichen Ressourcen. Im DFG-Schwerpunktprogramm 1542 wurden deshalb verschiedenste Ansätze erforscht, wie das Material effizienter eingesetzt und damit der Betonbau zukunftsfähig gemacht werden kann. Im vorliegenden Abschlussbericht zum SPP 1542 „Leicht Bauen mit Beton“ (gefördert von 2011 bis 2022) werden die wichtigsten Ergebnisse vorgestellt.:S. Scheerer, M. Curbach: Vorwort | Preface S.13 Teil 1: SPP-Projekte | Part 1: SPP projects A. M. Bauer, M. Breitenberger, K.-U. Bletzinger: Nichtlineare Optimierung geometrisch definierter Fugen von räumlich gekrümmten Betonfertigteilen mit isogeometrischen Verfahren | Non-linear optimization of geometrically defined joints of spatially curved prefabricated concrete elements with isogeometric analysis S.18 L. Ledderose, S. Lehmberg, F. Wirth, H. Kloft, H. Budelmann: Entwicklung neuartiger Verbindungen für komplexe Stab-, Flächen- und Raumtragelemente aus UHPFRC | Development of novel jointing systems for complex beam surface and spatial elements made of UHPFRC S. 50 J. D. van der Woerd, J. Hegger, R. Chudoba: Entwurf und Herstellung von dünnwandigen Faltwerken aus zementbasierten Verbundwerkstoffen | Design and construction of folded plate structures made of novel cementitious composites S. 90 A. Schmidt, M. Curbach: Querschnittsadaption für stabförmige Druckbauteile | Cross sectional adaption for rod-shaped elements in compression S. 118 M. Frenzel, K. Farwig, M. Curbach: Leichte Deckentragwerke aus geschichteten Hochleistungsbetonen | Lightweight ceiling structures made of layered high-performance concrete S. 144 S. Baron, J. Mainka, H. W. Hoffmeister, K. Dröder, H. Kloft: Non-Waste-Wachsschalungen: Neuartige Präzisions-Schalungen aus 100 % recycelbaren Industrie-Wachsen zur Herstellung von geometrisch komplexen Beton-Bauteilen | Non-Waste-Wax-Formwork: Novel precise formwork-technology on basis of 100% recyclable industrial wax for the fabrication of geometrically complex concrete elements S. 170 D. Busse, M. Empelmann: Ultraleichte, dünnwandige stabförmige Betonhohlbauteile | Ultra-light, thin-walled hollow concrete members S. 196 M. Henke, O. Fischer: Formoptimierte filigrane Stäbe aus UHPC und korrosionsfreier CFK-Bewehrung für variable räumliche Stabtragwerke | Shape optimized filigree rods made of UHPC and non-corrosive CFRP reinforcement for variable three-dimensional trusses S. 226 D. Schmeer, M. Wörner, H. Garrecht, O. Sawodny, W. Sobek: Effiziente automatisierte Herstellung multifunktional gradierter Bauteile mit mineralischen Hohlkörpern | Efficient automated production of multifunctional graded components with mineral hollow bodies S. 250 S. Illguth, D. Lowke, T. Kränkel, C. Gehlen: Schalentragwerke mit funktionaler Gradierung | Shell structures with functional grading S. 284 D. Weger, D. Talke, D. Lowke, K. Henke, C. Gehlen, S. Winter: Additive Fertigung frei geformter Betonbauteile durch selektives Binden mit calciumsilikatbasierten Zementen | Additive manufacturing of free formed concrete elements by selective binding with calcium silicate based cements S. 300 C.-A. Graubner, U. Knaack, T. Proske, B. Freund, M. Michel, S. Hickert: Grundlagen zur Entwicklung adaptiver Schalungssysteme für frei geformte Betonbauteile | Fundamental research towards an adaptive formwork system development for freeform concrete building components S. 328 A. Stark, J. Hegger: Sandwichbauteile mit gefalteten und gekrümmten Betondeckschichten | Sandwich panels with folded plate and curved concrete facings S.356 W. Jäger: Untersuchungen zu Trageigenschaften von plattenförmigen Betonleichtbauelementen in Kreuz-Kanal-Technologie | Investigations into the load-bearing properties of slab-shaped lightweight concrete elements in CC technology S.390 M. Schneider, H. Andrä, C. Kohlmeyer, S. Oster: Konstruktion und Optimierung von Klebeverbindungen für Platten- und Scheibenbauteile aus hochfestem Beton | Construction and optimization of adhesive joints for plate and shell construction elements composed of high performance concrete S.412 H. Funke, A. Ehrlich, L. Ulke-Winter, C. Petzoldt, S. Gelbrich, L. Kroll: Flexible GFK-Schalungen zur Herstellung von doppelt gekrümmten Beton-Leichtbauelementen mit stabilisierten Abstandsgewirken | Flexible GFRP-formwork for the production of double curved concrete lightweight elements with stabilized spacer fabrics S.436 H. Funke, L. Ulke-Winter, C. Petzoldt, C. Müller, S. Gelbrich, L. Kroll: Gekrümmte Beton-Leichtbauelemente mit bionisch inspirierten Krafteinleitungssystemen durch Einsatz flexibler GFK-Schalungen | Curved lightweight concrete structures with bionic inspired force transmission elements by the use of flexible GFRP-formworks S.452 L. Lohaus, J. Markowski: Wickelverstärkte Hybridrohre | Wrapping-reinforced hybrid tubes S.472 M. Schlaich, A. Goldack, J. P. Osman-Letelier, D. Lordick, K. Noack, M. Friedrich Eichenauer, R. Päßler, M. Pott: Methoden und Werkzeuge für Entwurf und Herstellung schalenartiger und dünnwandiger Betonbauteile mit Regelflächengeometrie | Methods and tools for the design and construction of thin-walled concrete structures with ruled surface geometry S.488 D. Lordick, D. Klawitter, M. Hagemann: Liniengeometrie für den Leichtbau | Line geometry for lightweight structures S.514 C. Kämper, T. Stallmann, P. Forman, J. Schnell, P. Mark: Leichte verformungsoptimierte Schalentragwerke aus mikrobewehrtem UHPC am Beispiel von Parabolrinnen solarthermischer Kraftwerke | Light-weight shape-optimised shell structures made from high-performance concrete for collector modules of parabolic trough power plants S.536 L. Zhou, J. Simon, S. Reese: Modellreduktion und Substrukturtechnik am Beispiel von modularen Schalentragwerken aus ultrahochfestem Beton | Model order reduction and substructures – application to modular shell structures made of ultra-high performance concrete S.590 M. Schnellenbach-Held, J.-E. Habersaat: Leichte Platten aus Beton mit biaxialem Lastabtrag als bionische Strukturen S.610 O. Gericke, D. Kovaleva, W. Haase, W. Sobek: Abfallfreie Herstellung von Betonbauteilen durch die Verwendung einer gefrorenen Sandschalung | Waste-free production of concrete components by means of a frozen sand formwork S.626 M. Wörner, D. Schmeer, H. Garrecht, O. Sawodny, W. Sobek: Optimalstrukturen aus funktional gradierten Betonbauteilen – Entwurf, Berechnung und automatisierte Herstellung | Optimal structures made of functional graded concrete – design, dimensioning and automated production S.642 Teil 2: Demonstratoren und Anschlussprojekte | Part 2: Demonstrators and follow-up projects D. Busse, L. Ledderose: uni-con² – universal concrete construction S.676 C. Müller, H. Funke, S. Gelbrich, L. Kroll: Carbonbeton-Schalendemonstrator | Shell demonstrator out of carbon reinforced concrete S.682 M. Koschemann, S. Scheerer: CarboLight Bridge – eine ultraleichte Konstruktion aus kohlefaserverstärktem und infraleichtem Beton | CarboLight Bridge – an ultra-lightweight construction made of carbon reinforced and infra-lightweight concrete for the German Museum in Munich S.686 S. Scheerer, B. Beckmann, J. Bielak, S. Bosbach, C. Schmidt, J. Hegger, M. Curbach: Konstruktionsstrategien für materialminimierte Carbonbetonstrukturen – Grundlagen für eine neue Art zu bauen | CRC/Transregio 280: Design strategies for material-minimised carbon reinforced concrete structures – principles of a new approach to construction S.700 D. Talke, D. Weger, K. Henke, T. Kränkel, D. Lowke, C. Gehlen, S. Winter: Industrieller 3D-Betondruck durch selektive Zementaktivierung – Verfahren, Material, Anwendungen | Industrial 3D concrete printing by selective cement activation – process, material, applications S.706 D. Schönfelder, H. Funke, S. Gelbrich, L. Kroll: Automatisierte Herstellungstechnologie zur Fertigung von dünnwandigen 3D-geformten Verbundelementen für nachhaltige energie-effiziente Fassadenlösungen – „GreenFACE“ | Automated manufacturing technology for the production of thin-walled 3D-shaped composite elements for sustainable, energy-efficient facade solutions – “GreenFACE“ S.710 A.-C. von der Heid, N. Will, J. Hegger: Weitspannende Sandwichelemente mit vorgespannten Deckschichten aus Carbonbeton | Wide-span sandwich elements with prestressed facings made of carbon reinforced concrete S.714 L. Ledderose, H. Kloft: Magnetische Ausrichtung von Mikro-Stahldrahtfasern in UHPFRC | Magnetic alignment of microsteel fibers in UHPFRC S.720 C. Petzoldt, C. Müller, H. Funke, S. Gelbrich, L. Kroll: Wiederverwendbare flexible GFK-Schalungen zur Herstellung von doppelt gekrümmten Beton-Leichtbauelementen | Re-usable and flexible GFRP formwork for the production of double curved concrete lightweight elements S.726 L. Lohaus, J. Markowski, R. Rolfes, F. F. Tritschel: UHFB-Drucktragglieder (basierend auf wickelverstärkten Hybridrohren) in voll digital datengestützter Fließfertigung als Basis für eine modulare Betonbauweise | UHPC compression rods (based on wrapped hybrid tubes) in fully digitally data-supported flow production as the basis for a modular concrete construction method S.734 P. Forman, T. Stallmann, P. Mark, J. Schnell: Auslegung von Parabolrinnen für Solarkraftwerke im Originalmaßstab S.738 P. Forman, S. Penkert, P. Mark, J. Schnell: Punktfokussierende Heliostaten aus Hochleistungsbeton | Point-focusing heliostats made from high-performance concretes S. 754 D. Kovaleva, O. Gericke, W. Sobek: Herstellung von biomimetischen und biologisch inspirierten (modularen) Strukturen | Fabrication of biomimetic and biologically inspired (modular) structures S.758 O. Gericke, W. Haase, W. Sobek: Sandschalung zur Herstellung von dünnwandigen Sandwiches aus Carbonbeton | Sand formwork for the production of thin-walled sandwiches made from carbon concrete S.762 D. Nigl, D. Schmeer, W. Haase, B. Schönemann, K. Lenz, S. Steier, O. Sawodny, P. Leistner, L. Blandini, W. Sobek: Integrale Planung und Herstellung von ressourceneffizienten Betonbauteilen aus mineralischer Faserverbundbewehrung und gradiertem Beton | Design and production of resource-efficient concrete components made of mineral fibre composite reinforcement and graded concrete S.766 Teil 3: Koordination | Part 3: Coordination S. Scheerer, M. Curbach: Koordination des SPP 1542 | Coordination of SPP 1542 S.774 / Reinforced concrete is the most widely used building material today. It can be produced universally and cheaply almost anywhere in the world. However, this is accompanied by high CO2 emissions and considerable consumption of natural resources. In the DFG Priority Programme 1542, a wide variety of approaches were therefore investigated to find out how the material can be used more efficiently and thus how concrete construction can be made fit for the future. This final report on SPP 1542 “Concrete Light“ (funded from 2011 to 2022) presents the most important results.:S. Scheerer, M. Curbach: Vorwort | Preface S.13 Teil 1: SPP-Projekte | Part 1: SPP projects A. M. Bauer, M. Breitenberger, K.-U. Bletzinger: Nichtlineare Optimierung geometrisch definierter Fugen von räumlich gekrümmten Betonfertigteilen mit isogeometrischen Verfahren | Non-linear optimization of geometrically defined joints of spatially curved prefabricated concrete elements with isogeometric analysis S.18 L. Ledderose, S. Lehmberg, F. Wirth, H. Kloft, H. Budelmann: Entwicklung neuartiger Verbindungen für komplexe Stab-, Flächen- und Raumtragelemente aus UHPFRC | Development of novel jointing systems for complex beam surface and spatial elements made of UHPFRC S. 50 J. D. van der Woerd, J. Hegger, R. Chudoba: Entwurf und Herstellung von dünnwandigen Faltwerken aus zementbasierten Verbundwerkstoffen | Design and construction of folded plate structures made of novel cementitious composites S. 90 A. Schmidt, M. Curbach: Querschnittsadaption für stabförmige Druckbauteile | Cross sectional adaption for rod-shaped elements in compression S. 118 M. Frenzel, K. Farwig, M. Curbach: Leichte Deckentragwerke aus geschichteten Hochleistungsbetonen | Lightweight ceiling structures made of layered high-performance concrete S. 144 S. Baron, J. Mainka, H. W. Hoffmeister, K. Dröder, H. Kloft: Non-Waste-Wachsschalungen: Neuartige Präzisions-Schalungen aus 100 % recycelbaren Industrie-Wachsen zur Herstellung von geometrisch komplexen Beton-Bauteilen | Non-Waste-Wax-Formwork: Novel precise formwork-technology on basis of 100% recyclable industrial wax for the fabrication of geometrically complex concrete elements S. 170 D. Busse, M. Empelmann: Ultraleichte, dünnwandige stabförmige Betonhohlbauteile | Ultra-light, thin-walled hollow concrete members S. 196 M. Henke, O. Fischer: Formoptimierte filigrane Stäbe aus UHPC und korrosionsfreier CFK-Bewehrung für variable räumliche Stabtragwerke | Shape optimized filigree rods made of UHPC and non-corrosive CFRP reinforcement for variable three-dimensional trusses S. 226 D. Schmeer, M. Wörner, H. Garrecht, O. Sawodny, W. Sobek: Effiziente automatisierte Herstellung multifunktional gradierter Bauteile mit mineralischen Hohlkörpern | Efficient automated production of multifunctional graded components with mineral hollow bodies S. 250 S. Illguth, D. Lowke, T. Kränkel, C. Gehlen: Schalentragwerke mit funktionaler Gradierung | Shell structures with functional grading S. 284 D. Weger, D. Talke, D. Lowke, K. Henke, C. Gehlen, S. Winter: Additive Fertigung frei geformter Betonbauteile durch selektives Binden mit calciumsilikatbasierten Zementen | Additive manufacturing of free formed concrete elements by selective binding with calcium silicate based cements S. 300 C.-A. Graubner, U. Knaack, T. Proske, B. Freund, M. Michel, S. Hickert: Grundlagen zur Entwicklung adaptiver Schalungssysteme für frei geformte Betonbauteile | Fundamental research towards an adaptive formwork system development for freeform concrete building components S. 328 A. Stark, J. Hegger: Sandwichbauteile mit gefalteten und gekrümmten Betondeckschichten | Sandwich panels with folded plate and curved concrete facings S.356 W. Jäger: Untersuchungen zu Trageigenschaften von plattenförmigen Betonleichtbauelementen in Kreuz-Kanal-Technologie | Investigations into the load-bearing properties of slab-shaped lightweight concrete elements in CC technology S.390 M. Schneider, H. Andrä, C. Kohlmeyer, S. Oster: Konstruktion und Optimierung von Klebeverbindungen für Platten- und Scheibenbauteile aus hochfestem Beton | Construction and optimization of adhesive joints for plate and shell construction elements composed of high performance concrete S.412 H. Funke, A. Ehrlich, L. Ulke-Winter, C. Petzoldt, S. Gelbrich, L. Kroll: Flexible GFK-Schalungen zur Herstellung von doppelt gekrümmten Beton-Leichtbauelementen mit stabilisierten Abstandsgewirken | Flexible GFRP-formwork for the production of double curved concrete lightweight elements with stabilized spacer fabrics S.436 H. Funke, L. Ulke-Winter, C. Petzoldt, C. Müller, S. Gelbrich, L. Kroll: Gekrümmte Beton-Leichtbauelemente mit bionisch inspirierten Krafteinleitungssystemen durch Einsatz flexibler GFK-Schalungen | Curved lightweight concrete structures with bionic inspired force transmission elements by the use of flexible GFRP-formworks S.452 L. Lohaus, J. Markowski: Wickelverstärkte Hybridrohre | Wrapping-reinforced hybrid tubes S.472 M. Schlaich, A. Goldack, J. P. Osman-Letelier, D. Lordick, K. Noack, M. Friedrich Eichenauer, R. Päßler, M. Pott: Methoden und Werkzeuge für Entwurf und Herstellung schalenartiger und dünnwandiger Betonbauteile mit Regelflächengeometrie | Methods and tools for the design and construction of thin-walled concrete structures with ruled surface geometry S.488 D. Lordick, D. Klawitter, M. Hagemann: Liniengeometrie für den Leichtbau | Line geometry for lightweight structures S.514 C. Kämper, T. Stallmann, P. Forman, J. Schnell, P. Mark: Leichte verformungsoptimierte Schalentragwerke aus mikrobewehrtem UHPC am Beispiel von Parabolrinnen solarthermischer Kraftwerke | Light-weight shape-optimised shell structures made from high-performance concrete for collector modules of parabolic trough power plants S.536 L. Zhou, J. Simon, S. Reese: Modellreduktion und Substrukturtechnik am Beispiel von modularen Schalentragwerken aus ultrahochfestem Beton | Model order reduction and substructures – application to modular shell structures made of ultra-high performance concrete S.590 M. Schnellenbach-Held, J.-E. Habersaat: Leichte Platten aus Beton mit biaxialem Lastabtrag als bionische Strukturen S.610 O. Gericke, D. Kovaleva, W. Haase, W. Sobek: Abfallfreie Herstellung von Betonbauteilen durch die Verwendung einer gefrorenen Sandschalung | Waste-free production of concrete components by means of a frozen sand formwork S.626 M. Wörner, D. Schmeer, H. Garrecht, O. Sawodny, W. Sobek: Optimalstrukturen aus funktional gradierten Betonbauteilen – Entwurf, Berechnung und automatisierte Herstellung | Optimal structures made of functional graded concrete – design, dimensioning and automated production S.642 Teil 2: Demonstratoren und Anschlussprojekte | Part 2: Demonstrators and follow-up projects D. Busse, L. Ledderose: uni-con² – universal concrete construction S.676 C. Müller, H. Funke, S. Gelbrich, L. Kroll: Carbonbeton-Schalendemonstrator | Shell demonstrator out of carbon reinforced concrete S.682 M. Koschemann, S. Scheerer: CarboLight Bridge – eine ultraleichte Konstruktion aus kohlefaserverstärktem und infraleichtem Beton | CarboLight Bridge – an ultra-lightweight construction made of carbon reinforced and infra-lightweight concrete for the German Museum in Munich S.686 S. Scheerer, B. Beckmann, J. Bielak, S. Bosbach, C. Schmidt, J. Hegger, M. Curbach: Konstruktionsstrategien für materialminimierte Carbonbetonstrukturen – Grundlagen für eine neue Art zu bauen | CRC/Transregio 280: Design strategies for material-minimised carbon reinforced concrete structures – principles of a new approach to construction S.700 D. Talke, D. Weger, K. Henke, T. Kränkel, D. Lowke, C. Gehlen, S. Winter: Industrieller 3D-Betondruck durch selektive Zementaktivierung – Verfahren, Material, Anwendungen | Industrial 3D concrete printing by selective cement activation – process, material, applications S.706 D. Schönfelder, H. Funke, S. Gelbrich, L. Kroll: Automatisierte Herstellungstechnologie zur Fertigung von dünnwandigen 3D-geformten Verbundelementen für nachhaltige energie-effiziente Fassadenlösungen – „GreenFACE“ | Automated manufacturing technology for the production of thin-walled 3D-shaped composite elements for sustainable, energy-efficient facade solutions – “GreenFACE“ S.710 A.-C. von der Heid, N. Will, J. Hegger: Weitspannende Sandwichelemente mit vorgespannten Deckschichten aus Carbonbeton | Wide-span sandwich elements with prestressed facings made of carbon reinforced concrete S.714 L. Ledderose, H. Kloft: Magnetische Ausrichtung von Mikro-Stahldrahtfasern in UHPFRC | Magnetic alignment of microsteel fibers in UHPFRC S.720 C. Petzoldt, C. Müller, H. Funke, S. Gelbrich, L. Kroll: Wiederverwendbare flexible GFK-Schalungen zur Herstellung von doppelt gekrümmten Beton-Leichtbauelementen | Re-usable and flexible GFRP formwork for the production of double curved concrete lightweight elements S.726 L. Lohaus, J. Markowski, R. Rolfes, F. F. Tritschel: UHFB-Drucktragglieder (basierend auf wickelverstärkten Hybridrohren) in voll digital datengestützter Fließfertigung als Basis für eine modulare Betonbauweise | UHPC compression rods (based on wrapped hybrid tubes) in fully digitally data-supported flow production as the basis for a modular concrete construction method S.734 P. Forman, T. Stallmann, P. Mark, J. Schnell: Auslegung von Parabolrinnen für Solarkraftwerke im Originalmaßstab S.738 P. Forman, S. Penkert, P. Mark, J. Schnell: Punktfokussierende Heliostaten aus Hochleistungsbeton | Point-focusing heliostats made from high-performance concretes S. 754 D. Kovaleva, O. Gericke, W. Sobek: Herstellung von biomimetischen und biologisch inspirierten (modularen) Strukturen | Fabrication of biomimetic and biologically inspired (modular) structures S.758 O. Gericke, W. Haase, W. Sobek: Sandschalung zur Herstellung von dünnwandigen Sandwiches aus Carbonbeton | Sand formwork for the production of thin-walled sandwiches made from carbon concrete S.762 D. Nigl, D. Schmeer, W. Haase, B. Schönemann, K. Lenz, S. Steier, O. Sawodny, P. Leistner, L. Blandini, W. Sobek: Integrale Planung und Herstellung von ressourceneffizienten Betonbauteilen aus mineralischer Faserverbundbewehrung und gradiertem Beton | Design and production of resource-efficient concrete components made of mineral fibre composite reinforcement and graded concrete S.766 Teil 3: Koordination | Part 3: Coordination S. Scheerer, M. Curbach: Koordination des SPP 1542 | Coordination of SPP 1542 S.774

This master thesis report describes the development process of a modernized handguard for the AK4B battle rifle, which is the main armament for the Swedish Home Guard. The project was carried out in cooperation with ALTEN Sweden AB. The goal of the project was to develop a new, competitive handguard design and to establish a complete design documentation as a foundation for production. This documentation consisted of a final material selection, process plan with suitable manufacturing methods and engineering drawings. The project was initiated with a problem definition to establish a thorough understanding of the product to be improved and enabling a determination of aspects that might be of importance to the product development. From this, research areas could be selected and studied to acquire necessary insights to complete the project goals. The product development process implemented is mainly inspired by Ulrich & Eppinger, and includes the stages concept development, detail design and testing & refinement. Thus, well-established methodology was implemented, ensuring credibility and a qualitative result. Throughout the stages ofthe product development process, a product specification was established, before generating concepts and selecting a final candidate which were refined based on the selection of materials and elaborated process plan. Finally, a verification of the requirements was concluded using several methods to prove the performance of the product. The results presents a developed product fulfilling established requirements and includes required documentation for production. Overall, the product is considered to have great potential for customer satisfaction, and to perform well in a final testing according to military standards.

This thesis aims to enhance the light ramp of Rottne Industri AB's harvester. To achieve this, various theories and methodologies were applied throughout the project. By employing a systematic product development process, the authors were able to minimize manufacturing costs while incorporating additional features for improved functionality. The newly developed design resulted in several significant improvements. The height of the light ramp was reduced by 15%, which not only aligns with the project’s goals but also contributes to better integration with the machine's overall structure. The manufacturing costs have been lowered, making the production process more economical and efficient. Furthermore, the lighting coverage has been enhanced to provide better illumination of the nearby area that is surrounding the harvester, thereby increasing visibility and safety for the operator. Overall, the project successfully met all the set objectives, delivering a more efficient, cost-effective, and functional light ramp design for Rottne Industri AB’s harvester.