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Institute of Machine Tools and Production Technology
Dr.-Ing. Annika Raatz, Dipl. Wirtsch.-Ing. Christian Löchte IWF – Technische Universität Braunschweig
Form-flexible Handling Technology (FormHand)
for Automation in RTM preforming
Agenda
Form-flexible Handling Technology (FormHand) for Automation in RTM preforming
Technische Universität Braunschweig Institute of Machine Tools and Production Technology (IWF)
- Department of Assembly and Production Automation
Current research focuses at IWF
(participation in research centers of TU Braunschweig)
Battery LabFactory Braunschweig (BLB)
Open Hybrid LabFactory – BMBF-ForschungsCampus
A novel handling concept – FormHand
Application of FormHand
Cooperation with Institute of Joining and Welding (ifs)
Integration of heating devices - Preforming with FormHand
Technische Universität Braunschweig
Founded in 1745 ca. 16.300 students 3.750 university employees 1.800 scientists 223 professors 120 institutes 65 study programmes 10 central facilities 6 faculties www.tu-braunschweig.de 0% 1% 2% 3% 4% 5% 6% 7% 8% A n te il a m B IP[Eurostat 2002] R&D density in European regions (percentage of
TECHNISCHE UNIVERSITÄT CAROLO-WILHELMINA BRAUNSCHWEIG
Institute of Machine Tools and Production Technology (IWF)
Institute management and research fields:
Production Technologies & Process Automation
Prof. Dr.-Ing. Klaus Dröder
Sustainable Manufacturing & Life Cycle Engineering
Prof. Dr.-Ing. Christoph Herrmann
Staff:
12 lecturers
~ 45 scientific assistants
18 employees (technical and administrative)
Institute of Machine Tools and Production Technology
Production Technology
- Dr. Hans-Werner Hoffmeister-
Cutting processes
Precision machining
Machining and processing of derived timber- and synthetic materials
Machine tool development
Modelling & simulation
Assembly & Production Automation
-Dr. Annika Raatz-
Development of automated handling- and assembly processes
Robot technology and assembly cells
Machine concepts for handling, assembly and automation
Sustainable Manufacturing
-Dr. Sebastian Thiede-
Energy- and resource efficiency in production
Improvement of machines and process chains and factories
Vision of “mineral oil free production“ – alternative metalworking fluids
Prof. Klaus Dröder
> Production Technologies & Process Automation <
Prof. Christoph Herrmann
> Sustainable Manufacturing & Life Cycle Engineering <
… … …
Life Cycle Engineering
-Dr. Tina Dettmer-
…
Life cycle analysis (life cycle assessment, life cycle costing)
Technology management
Planning and design of disassembly-/recycling systems
Methods and tools
supporting DFE and EMFA Institute of Machine Tools and
Open Hybrid
Lab
Factory
Research Group Assembly and Production Automation
Research fields:
Machine concepts (robots, grippers)
Assembly processes (automobile- and aircraft
production, precision applications)
Mechatronics for production automation
Annika Raatz, Dr.-Ing.
15 scientific assistants from the areas mechanical engineering, electrical engineering, informatics, physics, industrial engineering
Sonderforschungsbereich 516 Konstruktion und Fertigung aktiver Mikrosysteme
Overall Objectives
Research on reproducible production and process technologies
for “tailor-made” batteries with improved properties
Detailed Objectives
Scientific analysis of the entire value chain from active material preparation of electrodes, cell manufacturing and battery module as well as system integration
Development of process and production technology as well as
characterization methods for electrodes, cells and modules
Infrastructure
Building of an interdisciplinary research infrastructure for
electrode, cell and battery production and –diagnostics especially for automotive applications
Establishment of a dry room production environment, machinery and
diagnostics equipment
Overall Objectives
Application-oriented research on production technologies for economic and
multifunctional lightweight components Objectives
Sustainable fiber production
Inexpensive C-fiber production in Germany
Energy efficiency in the production process
Integrated Manufacturing Technologies
Parallelization of process steps
High – Volume Production
Process chains for the production of flat surface and profiled multi-material vehicle structures
Infrastructure and partner
Joint research of industry and scientific institutions in a joint infrastructure
Open Hybrid
Lab
Factory
Partnerschaft
C MPUS
öffentlich-private
FORSCHUNGS
für Innovationen
Open Hybrid
Lab
Factory
Integration of the expertise from scientific and industrial research in
an "open factory"
Setting of a public-private partnership, that
meets future technical challenges in an open
and versatile way.
Open
Hybrid
Lab
Factory
“Democratized” lightweight production through hybrid composite
structures made
of plastic, metal and textile structures
Settlement of the technology leaders along the complete process
chain - realized in Wolfsburg
Exemplary Process Chain in
Open Hybrid
Lab
Factory
Hybrid Component FRP
semi finished products (metallic, FRP) Functional elements
Fibres
Sheet products …
Injection molding and organo sheets
(sponsored by the state of Lower Saxony)
Production technologies for the preassembly of
multi-material preforms Thermoplastic, roll-formed
profiles in hybrid design
Handling, Draping and Preassembly
Planning, Handling & Bonding
Design and development of assessment tools for optimized multi-material
automotive component concepts in mass production
SpOr ProVor
TRoPHy MultiMaK
Exemplary Process Chain in
Open Hybrid
Lab
Factory
Hybrid Component FRP
semi finished products (metallic, FRP) Functional elements Fibres Sheet products … „Hybrid-Press“ Multipoint actuators
Integrated cooling / heating Modular tool concepts
Hybrid-Press- and Tool-Technology
Multifunctional and flexible handling concepts
Process control - concepts Mobile (autonomous) robots
Automation and handling technology
Research priorities
Research Group Assembly and Production Automation
Assembly
Assembly processes
Sensor guided assembly
Precision- and micro assembly
Limp / sensitive objects
Foils, textiles, solar cells High speed processes
Assembly of large components
Applications
Sensor assembly
Component assembly for e-mobility
Assembly composite material parts Automated preforming
Production Automation
Machine concepts
Structure synthesis | modelling
Closed-loop control | adaptronics | feed-forward control
Construction | simulation | prototypes
Robots, assembly cells
Industrial robots | parallel kinematic structures
Compliant mechanisms
Grippers and clamping mechanisms | end effectors
Smart Materials
Exemplary Process Chain in
Open Hybrid
Lab
Factory
Hybrid Component FRP
semi finished products (metallic, FRP) Functional elements
Fibres
Sheet products …
Multifunctional and flexible handling concepts
Process control - concepts Mobile (autonomous) robots
Automation and handling technology
RG Assembly and Production Automation topics in this process chain
New handling concepts
are requiered
Agenda
Form-flexible Handling Technology (FormHand) for Automation in RTM preforming
Technische Universität Braunschweig Institute of Machine Tools and Production Technology (IWF)
- Department of Assembly and Production Automation Current research focuses at IWF
(participation in research centers of TU Braunschweig) Battery LabFactory Braunschweig (BLB)
Open Hybrid LabFactory –BMBF-ForschungsCampus A novel handling concept – FormHand
Application of FormHand
Cooperation with Institute of Joining and Welding (ifs)
Integration of heating devices - Preforming with FormHand
General Preform Process and its Challenges
Motivation
Fiber reinforced composites (FRC) are considered as an innovative material for the production of
lightweight components in the future
The RTM (resin transfer molding) is mostly recommended for a high-volume production
So far, there is no mature automation technology for a high volume production available
Tool Preform
Mold Work piece
Objectives
Hardware realization of a flexible handling technology with integrated functionalities for the production of lightweight components
State of Research
Open challenges
Integration of all three functions in one tool: gripping – draping – bonding
Form-Flexibility of devices IGM Aachen
IPT Aachen
ITA Aachen
IWB Munich
The FormHand Concept
The FormHand Concept:
A cushion filled with granulate material in the combination with a low pressure vacuum gripper
The airflow is used for gripping objects of different material and for jamming of the granulate material inside the gripper cushion
FormHand – Form-flexible Handling Technology
Objectives
Gripping of limp material and irregular objects in different production scenarios
Using the form flexibility of FormHand for new applications, such as
draping of textile materials in the production of preforms
Approach
Material Selection:
Textile for the gripper cushion
Granulate material as a filler of the cushion
Simulation of the behavior of the granulate material
Modeling of FormHand for implementation in a robot control
1. Gripping and Draping with FormHand
Application of FormHand
Video
2. Draping with FormHand
Agenda
Form-flexible Handling Technology (FormHand) for Automation in RTM preforming
Technische Universität Braunschweig Institute of Machine Tools and Production Technology (IWF)
- Department of Assembly and Production Automation Current research focuses at IWF
(participation in research centers of TU Braunschweig) Battery LabFactory Braunschweig (BLB)
Open Hybrid LabFactory –BMBF-ForschungsCampus A novel handling concept – FormHand
Application of FormHand
Cooperation with Institute of Joining and Welding (ifs)
IWF and ifs enforce a joint research
in the
Open Hybrid
Lab
Factory
Research Cooperation
IWF has know-how in Automation and Handling Technology
ifs has know-how in Joining and Composite Technology
Objectives of Cooperation
Preforming with integrated functionalities in one tool: handling – draping – bonding
Handling Technologies with integrated Functionality for the
Production of Composite Components
Motivation
Fiber reinforced composites (FRC) are considered as an innovative
material for the production of lightweight components in the future
There is a high demand of FRC for a production at large scale
So far, there is no mature automation technology for a high volume
production available
Objectives
Hardware realization of flexible handling technology with integrated functionalities for the production of lightweight components
Preforming with a form-flexible gripper with integrated heating technology
Approaches
Identification of process parameters for an automated preform process
Investigation of the handling and draping processes for the production based on textile materials
Construction and realization of grippers for the preform production
tool preform
Mold Work piece
Innovative Handling Technology with Integration of Functions
State-of-the-Technology:
Vacuum-Gripping of
limp textiles
Innovation 2:
Form-Flexible Gripping
(self-adjusting gripping and draping)
Innovation 1:
Integration of heating devices into the
gripper, combination with robotics
Vacuum Connection
Vacuum Gripper
Integrated heating Form-Flexibility with integrated heating
Reducing Process Time:
Integration of heating technologies
Heating textile contacted with metal
conductors for initial experiments
These activities are carried out by the research partner ifs
Concepts for the integration heating devices into
the gripper cushion
FormHand in the preforming process
Summary and Outlook
Open Hybrid
Lab
Factory
was successful started in March 2013
IWF is taking part in a research cooperation with ifs
From this cooperation a new handling concept emerges
FormHand concept was discussed and a hardware realization of
the concept was presented
Further development of FormHand within the activities in the
Open Hybrid
Lab
Factory
:
Constructive aspects
Selection of materials: Cushion and Filling
Optimization of general design
Further integration of functionalities (actuators, sensors …)
Process design / control
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Institute of Machine Tools and Production Technology
Dr.-Ing. A. Raatz, Dipl. Wirtsch.-Ing. C. Löchte, Dipl.-Ing. F. Dietrich, Prof. K. Dröder (IWF) Dipl.-Ing. H. Kunz, Dr. F. Fischer (ifs)
Form-flexible Handling Technology (FormHand)
for Automation in RTM preforming
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Institute of Machine Tools and Production Technology
Dr.-Ing. A. Raatz: a.raatz@tu-braunschweig.de
Dipl. Wirtsch.-Ing. C. Löchte: c.loechte@tu-braunschweig.de Technische Universität Braunschweig
Institut für Werkzeugmaschinen und Fertigungstechnik
