for Automation in RTM preforming

Transcription

Institute of Machine Tools and
Production Technology
Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
Form-flexible Handling Technology (FormHand)
Dr.-Ing. Annika Raatz, Dipl. Wirtsch.-Ing. Christian Löchte
IWF – Technische Universität Braunschweig
CFK-Convention 2013 – Stade
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
 Summary and Outlook
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 2
Institut für Werkzeugmaschinen
und Fertigungstechnik
Technische Universität Braunschweig
 Founded in 1745
TECHNISCHE UNIVERSITÄT CAROLO-WILHELMINA
BRAUNSCHWEIG
 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
8%
7%
6%
Anteil am BIP
5%
4%
3%
2%
1%
0%
[Eurostat 2002] R&D density in European regions (percentage of
GDP). The Braunschweig region is nationally ranked on first
place with 7,1% followed by Northern Finland (4,2%) and East
England (3,9%).
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)
ca. 80 students
Institute of Machine Tools and Production Technology
Prof. Klaus Dröder
> Production Technologies & Process Automation <
- 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
Prof. Christoph Herrmann
> Sustainable Manufacturing & Life Cycle Engineering <
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
 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
…
…
…
…
Life Cycle Engineering
-Dr. Tina Dettmer-
Research Group Assembly and Production Automation
Annika Raatz, Dr.-Ing.
15 scientific assistants from the areas
mechanical engineering, electrical
engineering, informatics, physics,
industrial engineering
Research fields:
 Machine concepts (robots, grippers)
 Assembly processes (automobile- and aircraft
production, precision applications)
 Mechatronics for production automation
Open Hybrid
LabFactory
Sonderforschungsbereich 516
Konstruktion und Fertigung
aktiver Mikrosysteme
Battery LabFactory Braunschweig
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
Open Hybrid LabFactory
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
FORSCHUNGS
C MPUS
öffentlich-private Partnerschaft
für Innovationen
Funding: 15 years, 2 Mio€/a
Process chains for the production of flat surface and profiled multimaterial vehicle structures
Infrastructure and partner
 Joint research of industry and scientific institutions in a joint infrastructure
Open Hybrid LabFactory
Open
Integration of the expertise from scientific and industrial research in
an "open factory"
Hybrid
“Democratized” lightweight production through hybrid composite
structures made of plastic, metal and textile structures
LabFactory
Settlement of the technology leaders along the complete process
chain - realized in Wolfsburg
Setting of a public-private partnership, that
meets future technical challenges in an open
and versatile way.
Exemplary Process Chain in Open Hybrid LabFactory
FRP
semi finished products (metallic, FRP)
Functional elements
Fibres
Sheet products
…
Hybrid
Component
MultiMaK
TRoPHy
ProVor
SpOr
Design and development of
assessment tools for
optimized multi-material
automotive component
concepts in mass production
Thermoplastic, roll-formed
profiles in hybrid design
Production technologies for
the preassembly of multimaterial preforms
Injection molding and
organo sheets
(sponsored by the
state of Lower Saxony)
Planning, Handling
& Bonding
Handling,
Draping and
Preassembly
FRP
Functional elements
Fibres
Sheet products
…
Hybrid
Component
IWF topics in this process chain
Automation and handling technology
Hybrid-Press- and Tool-Technology
„Hybrid-Press“
Multipoint actuators
Integrated cooling / heating
Modular tool concepts
Multifunctional and flexible
handling concepts
Process control - concepts
Mobile (autonomous) robots
Quelle: Siempelkamp
Quelle: H+R
Research priorities
Research Group Assembly and Production Automation
Assembly
 Assembly processes
Production Automation
 Machine concepts
 Sensor guided assembly
 Structure synthesis | modelling
 Precision- and micro assembly
 Closed-loop control | adaptronics |
feed-forward control
 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
 Construction | simulation | prototypes
 Robots, assembly cells
 Industrial robots | parallel kinematic
structures
 Compliant mechanisms
 Grippers and clamping mechanisms
| end effectors
 Smart Materials
 Shape-memory alloys, Piezo crystals
FRP
Functional elements
Fibres
Sheet products
…
Hybrid
Component
RG Assembly and Production Automation topics in this process chain
Automation and handling technology
Multifunctional and flexible
handling concepts
Process control - concepts
Mobile (autonomous) robots
New handling concepts
are requiered
Quelle: H+R
Agenda
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
Preforming attracts many research activities
IPT Aachen
ITA Aachen
IGM Aachen
IWB Munich
Open challenges
 Integration of all three functions in one tool: gripping – draping – bonding
 Form-Flexibility of devices
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
 An integration of additional functions into the gripper cushion extends the concept of FormHand
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

Hardware realization and test of the concept
Application of FormHand
1. Gripping and Draping with FormHand
Video
2. Draping with FormHand
3. FormHand as a Form Tool
Video: The FormHand Concept
Agenda
IWF and ifs enforce a joint research
in the Open Hybrid LabFactory
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
Automation and Handling Technology
Joining and Composite Technology
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
tool
preform
 There is a high demand of FRC for a production at large scale
Mold
Work piece
 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
Form-Flexibility with integrated heating
Innovative Handling Technology with Integration of Functions
Vacuum Connection
State-of-the-Technology:
Vacuum-Gripping of
limp textiles
Vacuum Gripper
Innovation 1:
Integration of heating devices into the
gripper, combination with robotics
Integrated heating
Innovation 2:
Form-Flexible Gripping
(self-adjusting gripping and draping)
Form-Flexibility with integrated heating
Reducing Process Time:
 Integration of Functions: Gripping, Draping and Heating
Integration of heating technologies
These activities are carried out by the research partner ifs
Concepts for the integration heating devices into
the gripper cushion
Heating textile contacted with metal
conductors for initial experiments
Gerster TechTex GmbH (Germany)
FormHand in the preforming process
These activities are carried out by the research partner ifs
Summary and Outlook


Open Hybrid LabFactory 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 LabFactory:
Constructive aspects
 Selection of materials: Cushion and Filling
 Optimization of general design
 Further integration of functionalities (actuators, sensors …)
Process design / control
 Distribution of granulate material while draping
 Mode selection and control of process forces
Thank you for your attention!
Form-flexible Handling Technology (FormHand)
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)
Contact: Annika Raatz, E-Mail: a.raatz@tu-braunschweig.de
Contact Information
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
Langer Kamp 19b
38106 Braunschweig

for Automation in RTM preforming

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