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Harfensteller, Felix; Henning, Stefan; Zentner, Lena; Husung, Stephan;
Modeling of corner-filleted flexure hinges under various loads. - In: Mechanism and machine theory, Bd. 175 (2022), 104937, S. 1-11

Compliant mechanisms are widely applied in precision engineering, measurement technology and microtechnology, due to their potential for the reduction of mass and assembly effort through the integration of functions into fewer parts and an increasing motion repeatability through less backlash and wear, if designed appropriately. However, a challenge during the design process is the handling of the multitude of geometric parameters and the complex relations between loads, deformations and strains. Furthermore, some tasks such as the dimensioning by means of optimization or the modeling for a controller design require a high number of analysis calculations. From this arises the need for sufficient computational analysis models with low calculation time. Existing studies of analysis models are mostly based on selected load cases, which may limits their general validity. The scope of this article is the comparison of models for the analysis of corner-filleted flexure hinges under various loads, to determine their advantages, disadvantages and application fields. The underlying methods of the study can further be used to evaluate future models based on a broad selection of possible load cases.
Koch, Yanik; Husung, Stephan; Röhnert, Felix; Mahboob, Atif; Frank, M. G.; Kirchner, Eckhard;
A method for the support of the design for Digital Twin solution and its application on a gearbox system. - In: Proceedings of the Design Society, ISSN 2732-527X, Bd. 2 (2022), S. 1609-1618

The information from Real Twins are increasingly used to construct Digital Twins. Acquisition of information from the Real Twin or in other words performing measurements on the Real Twin may lead to effects in the working of Real Twin. For instance, the introduction of sensors may impair certain functions of a Real Twin. Therefore, it is important to analyse the effect of any change that is performed on the Real Twin for achieving the Digital Twin. In this paper, a method for Digital Twin solution is presented that address these aspects as well as its use is demonstrated by a case example.
Mahboob, Atif; Husung, Stephan;
A modelling method for describing and facilitating the reuse of SysML models during design process. - In: Proceedings of the Design Society, ISSN 2732-527X, Bd. 2 (2022), S. 1925-1934

MBSE and SysML are increasingly finding their applications in industry as well as in academia. The reuse of the information described in SysML models depends, among others, on the modelling methods, management of dependencies between elements and on the needed remodelling effort. In this paper, a modelling method is presented that address the reuse of SysML models and descriptions as well as reuse of model variants in SysML. A case example is presented to explain the modelling methods and the gained experience is summarised in the form of general recommendations for further use.
Husung, Stephan; Weber, Christian; Mahboob, Atif;
Integrating model-based design of mechatronic systems with domain-specific design approaches. - In: Proceedings of the Design Society, ISSN 2732-527X, Bd. 2 (2022), S. 1895-1904

In addition to the known approaches for product development new or supplementary approaches have emerged. An important approach in this field is Systems Engineering (SE) and Model-Based Systems Engineering. Through these approaches, new procedures, level-focused description concepts and terms come into product development. However there are still some uncertainties as to how the known approaches of product development can be combined with the SE approaches. This paper aims to show how the known development approaches can be extended by and integrated with SE approaches.
Streck, Marco; Husung, Stephan; Hassler, Julien;
Determination and systematization of load situations for eBike drive units as basis for their design and optimization. - In: Achte IFToMM D-A-CH Konferenz 2022, (2022), S. 1-6
Husung, Stephan; Weber, Christian; Mahboob, Atif;
Model-based systems engineering: a new way for function-driven product development. - In: Design Methodology for Future Products, (2022), S. 221-241

Since the 1950ies Design Theory and Methodology has described product and system development as a process that goes through the stages of requirements definition, considerations of functions, allocation of solution principles and, finally, detailing. Computer support of this process has more or less evolved backwards: Starting with manufacturing information (i.e. supporting processes after product development), going through geometric modelling to simulation - which is basically our present state. Functional modelling and requirements management has been very difficult to realise with conventional methods. Today, Model-Based Systems Engineering (MBSE) offers new ways to come to a holistic coverage of the product development process providing and - very importantly - linking model elements for all of its stages. Starting from the needs, as seen from Design Theory and Methodology, this article describes the current state of MBSE as a new, integrative approach for product and system development and identifies needs for further progress in this field.
Mahboob, Kamran; Mahboob, Atif; Husung, Stephan;
Virtual Reality (VR) for the support of the analysis and operation of a solar thermal tower power plant. - In: 41st Computers and Information in Engineering Conference (CIE), (2021), DETC2021-70202, V002T02A080, 9 Seiten

Harfensteller, Felix; Henning, Stefan; Linß, Sebastian;
Comparison of nonlinear continuum beam models with finite beam models for the analysis of compliant mechanisms :
Vergleich nichtlinearer Kontinuums-Balkenmodelle mit finiten Balkenmodellen für die Analyse nachgiebiger Mechanismen. - In: IFToMM D-A-CH Konferenz 2021 der IFTOMM Member Organizations Austria, Germany, Switzerland, (2021), S. 58-61

Nachgiebige Mechanismen haben sich für eine Vielzahl von Anwendungen in der Feinwerk-, Mess- und Mikrotechnik etabliert. Für den iterativen Entwurf sowie die Optimierung von nachgiebigen Mechanismen besteht ein Bedarf an zeiteffizienten Analysemodellen mit möglichst geringen Abweichungen zum gefertigten Mechanismus. Hierfür wurden eine Reihe verschiedener Modellierungsansätze zur Beschreibung des Bewegungsverhaltens entwickelt und untersucht, unter denen nichtlineare Kontinuums-Balkenmodelle und nichtlineare finite Balkenmodelle ein hohes Potenzial zeigen. Trotz der ähnlichen Ansätze der Balkentheorie ergeben sich Unterschiede im Einsatz beider Modelle, die aufbauend auf den Ergebnissen bestehender Veröffentlichungen im Rahmen dieses Beitrages näher diskutiert werden.
Husung, Stephan; Weber, Christian; Mahboob, Atif; Kleiner, Sven;
Using model-based systems engineering for need-based and consistent support of the design process. - In: Proceedings of the Design Society, ISSN 2732-527X, Bd. 1 (2021), S. 3369-3378

Model-Based Systems Engineering (MBSE) is an efficient approach to support product development in order to meet today's challenges. The MBSE approach includes methods and, above all, modelling approaches of the technical system with the aim of continuous use in development. The objective of this paper is to use the potential of the MBSE models and to show the added value of such models on the system level when used as a single source. With this objective, this paper presents a three-step approach to systematically identify and apply meaningful modelling approaches within MBSE, based on the needs during the development process. Furthermore, an FMEA example is included in this paper to elaborate the use of MBSE in the system failure analysis.
Gräser, Philipp; Linß, Sebastian; Harfensteller, Felix; Torres, Mario; Zentner, Lena; Theska, René;
High-precision and large-stroke XY micropositioning stage based on serially arranged compliant mechanisms with flexure hinges. - In: Precision engineering, Bd. 72 (2021), S. 469-479

Compliant mechanisms are state of the art in micropositioning stages due to their many beneficial features. However, their design usually compromises between motion range, motion accuracy and design space, while mechanisms with distributed compliance are mostly applied. The further use of flexure hinges with common notch shapes strongly limits the stroke in existing high-precision motion systems. Therefore, this paper presents a high-precision compliant XY micropositioning stage with flexure hinges capable of realizing a motion range of ± 10 mm along both axes. The stage is based on a novel plane-guidance mechanism, which is optimized to realize a precise rectilinear motion of the coupler link while keeping the rotation angles of all hinges below 5˚. The XY motion is then achieved by coupling two of these mechanisms in a serial arrangement. Next, the synthesis of the monolithic XY stage is realized by replacing all revolute joints of the rigid-body model with flexure hinges using optimized power function notch shapes. Emphasis is also placed on the embodiment design of the stage and the actuator integration to minimize possible error sources. Finally, the quasi-static behavior of the compliant stage is characterized by a simulation with a 3D FEM model and by an experimental investigation of a prototype. According to the results, the developed compliant XY micropositioning stage achieves a maximum positioning deviation of less than 10 [my]m in both axes and a yaw error of less than 100 [my]rad over a working range of 20 mm × 20 mm with a comparably compact design of the compliant mechanism of 224 mm × 254 mm.