This approach analyses the differences between a single flank rolling test and an analytical simulation based on optical measurement data of micro gears. The focus is on a signal-based comparison of the rolling behaviour. Using methods in the time and frequency domain as well as the derivation of methods such as cross-correlation, the capability of this simulative approach is qualified. Due to short measurement times with high correlations to the test rig, an inline integration of this analytical simulation for quality assurance of micro gears in series production will be implemented as part of a holistic approach.

The rapidly advancing trend towards miniaturization in the series production of gears confronts quality assurance with new challenges. In this context, metrological technologies as well as expertise from the field of macro gears can only be transferred to a limited extent. Inline integration of metrology into micro gear production has not yet been implemented in a practicable way. This publication extends the current limits of micro gear quality assurance to date by qualifying the optical method of focus variation technology for complete inline measurements of micro gears in series production time. In detail, this work includes the development of a measurement program by means of Design of Experiments, the establishment of a practicable cleaning process, the evaluation of resulting measurement uncertainties, and a process capability analysis. Consequently, the focus variation technology is qualified for fast, three-dimensional measurements of micro gears with respectively low measurement uncertainties.

In lightweight design, developers are used to face the conflicting objectives of functional fulfillment, economic performance, and sustainability. Against this background, however, a clearly structured approach for the satisfied use of lightweight engineering methods within a product development is still missing. Thus, this contribution deals with the fundamental conception and first implementation of a systematic development methodology covering the disciplines of mechanics, electrics/electronics and software just like the focus on an integrated view on product, production and material aspects. To ensure an application-specific manifestation of the product development process for three different use cases from small and medium-sized enterprises but also large corporations in the area of prosthetics, bike construction and plant engineering, the individually developed methods and tools are generalized in order to make them adaptable to a wide variety of industries. As a result, one lightweight-specific method or tool (e.g., function mass analysis, “PPM solution correlator“ or “2D layout & weight drafting”) is introduced in more detail for all stages of the technically extended RFL(T)P approach derived from model-based systems engineering (MBSE).

Future developments lead to increasing demands on mechatronic integrated devices (MID). Therefore, ceramics have to be used as substrate material and conductor tracks have to be located in the interior of components to be sufficiently protected. A process combination of vat photopolymerization (VPP-LED) and vacuum die casting is investigated for realizing such structures. First, optimized process parameters are derived by studying the filling behavior of straight capillaries. Subsequently, the results are transferred to complex additively manufactured substrates to derive design guidelines.

Competitive remanufacturing of used products with uncertain conditions requires a high degree of flexibility and responsiveness. This article describes an integrated control architecture for a modular, agile disassembly system with autonomous product inspection and learning production resources. The approach includes a material flow control and vertically-integrated sub-architectures to control the station and intralogistics operations.