Remote Handling and Logistics under Extreme Boundary Conditions (FLX)

Department of FLX

The traditional competencies at the IFL in the fields of materials handling and logistics systems have been used for several years in the field of maintenance of fusion test facilities and power plants. In this context, the FLX department is working on several fusion research projects. The department deals with issues related to remote handling and transport of activated materials from a design point of view, as well as the applicability of sometimes extreme boundary conditions.
In order to achieve the highest possible plant availability and thus plant economy, we optimize the corresponding maintenance processes by means of logistic methods, modeling and simulation. This includes, among other things, the determination of the layout, the transport routes and the use of resources in the best suitable manner. Among other things, these methods are used in the planning of the large multinational fusion projects IFMIF, DONES, ITER and DEMO.

In addition to the FUSION-related tasks, the work in the FLX department includes the development and design of novel material handling systems. With competencies in the fields of materials handling and logistics systems, innovative approaches for reducing the weight of large-scale conveyor components (e.g. segmented construction of trussed crane bridges) are developed.

On the basis of a mechanical model, which considers the relevant system parameters, static as well as dynamic properties are investigated.

For guidance tasks such as the guideway of the lift truck on a stacker crane mast or the guideway of the cat on the segmented truss bridge, the use of fiber composite materials and the interaction with guide and load rollers is being researched.

Particular attention is paid to the research of the contact problem of roller/guideway and the optimization of the geometry of the bearing surface.

The goal is the development of higher loadable functional elements (roller/guideway) as a basis for new weight and energy optimized constructions with fiber reinforced composites (FRC) in intralogistics.

Department of FLX – Completed Research Projects
Title Contact


Creation of a Development Platform for Remote Maintenance Solutions in Fusion Power Plants
Hall, S.; Hora, M.; Fischer, G.; Köhler, S.; Rauscher, F.; Lehmann, T.; Oellerich, J.; Crofts, O.; Torrance, M.; Drumm, B.
2024. IEEE Transactions on Plasma Science, 1–6. doi:10.1109/TPS.2024.3359278
Unterirdischer Warentransport Landeshauptstadt Stuttgart - Machbarkeitsstudie
Dehdari, P.; Rauscher, F.; Walz, M.; Oellerich, J.; Furmans, K.; Heusser, M.; Unverfärth, K.; Seeger, C.
2023. KIT Scientific Publishing. doi:10.5445/KSP/1000162868
Concept of Contamination Control Door for DEMO and Proof of Principle Design
Wang, Y.; Oellerich, J.; Baars, C.; Mittwollen, M.
2023. Journal of Nuclear Engineering, 4 (1), 228–240. doi:10.3390/jne4010018
Logistics and maintenance research activities for DONES facility
Arranz, F.; Lehmann, T.; Rauscher, F.; Fischer, G.; Koehler, S.; Garrido, J.; Rouret, M.; Sanchez-Herranz, D.
2023. Fusion Engineering and Design, 192, Art.-Nr.: 113630. doi:10.1016/j.fusengdes.2023.113630
Design and Evaluation of a Passive Gripper for Remote Manipulation Tasks
Redondo Gallego, V.; Delgado Jiménez, M. del V.; Miccichè, G.; Mittwollen, M.; Sebastián, J. M.; Sánchez-Urán, M. A.; Ferre, M.
2023. ROBOT2022: Fifth Iberian Robotics Conference – Advances in Robotics, Volume 1. Ed.: D. Tardioli, 53–64, Springer International Publishing. doi:10.1007/978-3-031-21065-5_5
Development of Mechanical Pipe-Connection Design for DEMO
Milushev, V.; Azka, A.; Mittwollen, M.
2023. Journal of Nuclear Engineering, 4 (1), 111–126. doi:10.3390/jne4010008
Using Deep Neural Networks for Scheduling Resource-Constrained Activity Sequences. PhD dissertation
Pagani, P.
2022, October 17. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000151132
EU DEMO Remote Maintenance System development during the Pre-Concept Design Phase
Crofts, O.; Loving, A.; Torrance, M.; Budden, S.; Drumm, B.; Tremethick, T.; Chauvin, D.; Siuko, M.; Brace, W.; Milushev, V.; Mittwollen, M.; Lehmann, T.; Rauscher, F.; Fischer, G.; Pagani, P.; Wang, Y.; Baars, C.; Vale, A.
2022. Fusion Engineering and Design, 179, Art.-Nr. 113121. doi:10.1016/j.fusengdes.2022.113121
Concept of Contamination Control Door for DEMO and Proof of Principle Design
Wang Y.; Baars, C.; Mittwollen, M.; Oellerich, J.; Madzharov, V.
2022. 32nd Symposium on Fusion Technology (SOFT 2022), Dubrovnik, Croatia, September 18–23, 2022
Advanced design of the ITER core CXRS shutter and integration into the diagnostic shield module of the Upper Port Plug No. 3
Friese, S.; Mertens, P.; Mlynczak, K.; Krimmer, A.; Ivashov, I.; Linsmeier, C.; Ortmanns, T.; Offermanns, G.; Park, J. H.; Leichtle, D.; Mittwollen, M.; Oellerich, J.
2021. Fusion engineering and design, 168, Art.-Nr.: 112391. doi:10.1016/j.fusengdes.2021.112391
Generating Synthetic Training Data for Assembly Processes
Dümmel, J.; Kostik, V.; Oellerich, J.
2021. Advances in Production Management Systems. Artificial Intelligence for Sustainable and Resilient Production Systems. IFIP WG 5.7 International Conference, APMS 2021, Nantes, France, September 5–9, 2021, Proceedings, Part IV. Ed.: A. Dolgui, 119–128, Springer International Publishing. doi:10.1007/978-3-030-85910-7_13
A digital twin concept for the development of a DEMO maintenance logistics modelling tool
Rauscher, F.; Fischer, G.; Lehmann, T.; Zapata, J. J.; Pagani, P.; Loving, A.
2021. Fusion Engineering and Design, 168, Art.-Nr.: 112399. doi:10.1016/j.fusengdes.2021.112399
Modular transportation concept for application in DEMO Oriented Neutron Source (DONES)
Lehmann, T.; Rauscher, F.; Oellerich, J.; Fischer, G.; Zapata, J.
2021. Fusion engineering and design, 164, Article: 112199. doi:10.1016/j.fusengdes.2020.112199
Design status of the ITER core CXRS diagnostic setup
Krimmer, A.; Balboa, I.; Conway, N. J.; De Bock, M.; Friese, S.; Le Guern, F.; Hawkes, N. C.; Kampf, D.; Krasikov, Y.; Mertens, P.; Mittwollen, M.; Mlynczak, K.; Oellerich, J.; Szarvas, G.; Weinhorst, B.; Linsmeier, C.
2019. Fusion engineering and design, 146 (Part A), 228–231. doi:10.1016/j.fusengdes.2018.12.026
The remote handling system of IFMIF-DONES
Miccichè, G.; Ascott, M.; Bakic, A.; Bernardi, D.; Brenosa, J.; Coloma, S.; Crofts, O.; Di Gironimo, G.; Ferre, M.; Fischer, G.; Ibarra, A.; Karap, A.; Kiss, I. G.; Kunert, C.; Lorenzelli, L.; Mitchell, G.; Mittwollen, M.; Pagani, P.; Papa, S.; Porempovics, G.; Tadic, T.; Matyas, T.
2019. Fusion engineering and design, 146, 2786–2790. doi:10.1016/j.fusengdes.2019.01.112
Maintenance logistics for IFMIF-DONES
Mittwollen, M.; Fischer, G.; Pagani, P.; Kunert, C.; Oellerich, J.; Lehmann, T.; Micciche, G.; Ibarra, A.
2019. Fusion engineering and design, 146 (B), 2743–2747. doi:10.1016/j.fusengdes.2019.05.017
Modellierung und Untersuchung eines segmentierten Fachwerksystems für Brückenkranträger
Oellerich, J.; Bolender, S.; Golder, M.; Furmans, K.
2018. Logistics journal / Proceedings, 2018, 8 S. doi:10.2195/lj_Proc_oellerich_de_201811_01
System zur reproduzierbaren, automatischen und sicheren Stapelung von Gitterboxen mit einem Brückenkran – KrasS
Bolender, S.; Oellerich, J.; Braun, M.; Golder, M.; Furmans, K.
2018. Logistics journal / Proceedings, 2018. doi:10.2195/lj_Proc_bolender_de_201811_01
Dezentrale mechanische Fördertechnik - modulare skalierbare Segmente eines Brückenkranträgers
Braun, M.; Bolender, S.; Oellerich, J.; Golder, M. O.
2018. Ingenieur-Spiegel, (3 / 2018), 38–39
Performance evaluation of closed-loop logistics systems with generally distributed service times
Epp, M.; Pagani, P.; Stoll, J.; Scherer, S.; Rohlehr, C.; Furmans, K.
2017. Proceedings of the Second KSS Research Workshop : Karlsruhe, Germany, February 2016. Ed.: P. Hottum, 120–130, Karlsruher Institut für Technologie (KIT)
Skalierbarer modularer Brückenkranträger in Segmentbauweise
Bolender, S.; Oellerich, J.; Braun, M.; Golder, M.
2017. Logistics journal / Proceedings, 1–8. doi:10.2195/lj_Proc_bolender_de_201710_01
Performance evaluation of closed-loop logistics systems with generally distributed service times
Epp, M.; Pagani, P.; Stoll, J.; Scherer, S.; Rohlehr, C.; Furmans, K.
2016. Proceedings of the Karlsruhe Service Summit Research Workshop 2016, KSS 2016, Karlsruhe, 25.-26. Februar 2016
Development of a zonal applicability tool for remote handling equipment in DEMO
Madzharov, V.; Mittwollen, M.; Leichtle, D.; Hermon, G.
2015. Fusion engineering and design, 98-99, 1543–1547. doi:10.1016/j.fusengdes.2015.06.057
A decomposition approach for the calculation of the cycle time distribution of closed queueing systems
Epp, M.; Stoll, J.; Scherer, S.; Pagani, P.; Furmans, K.
2015. 10th Conference on Stochastic Models of Manufacturing and Service Operations, June 1-6, 2015, Volos, Greece, 59–66, University of Thessaly Press
Entwicklung eines Verfahrens und einer Anlage zum Sortieren von Altkorken
Schönung, F.; Mittwollen, M.; Furmans, K.
2006. Tagungsbeiträge des 2. Fachkolloquium der Wissenschaftliche Gesellschaft Technische Logistik (WGTL), Dresden, 08./09. Juni 2006. Hrsg.: H.-G. Marquardt, 159–170, Wissenschaftliche Gesellschaft für Technische Logistik e.V. (WGTL)