Institute of Machine Tools and Production Technology Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen Form-flexible Handling Technology (FormHand) for Automation in RTM preforming 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 CFK-Convention June 17, 2013 Slide 2
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 TECHNISCHE UNIVERSITÄT CAROLO-WILHELMINA BRAUNSCHWEIG www.tu-braunschweig.de 8% 7% 6% 5% Anteil am BIP 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%). CFK-Convention June 17, 2013 Slide 3
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 CFK-Convention June 17, 2013 Slide 4
Institute of Machine Tools and Production Technology Institute of Machine Tools and Production Technology Prof. Klaus Dröder > Production Technologies & Process Automation < Prof. Christoph Herrmann > Sustainable Manufacturing & Life Cycle Engineering < Production Technology - Dr. Hans-Werner Hoffmeister- Assembly & Production Automation -Dr. Annika Raatz- Sustainable Manufacturing -Dr. Sebastian Thiede- Life Cycle Engineering -Dr. Tina Dettmer- Cutting processes Precision machining Machining and processing of derived timber- and synthetic materials Machine tool development Modelling & simulation Development of automated handling- and assembly processes Robot technology and assembly cells Machine concepts for handling, assembly and automation 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 CFK-Convention June 17, 2013 Slide 5
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 CFK-Convention June 17, 2013 Slide 6
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 CFK-Convention June 17, 2013 Slide 7
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 Process chains for the production of flat surface and profiled multimaterial vehicle structures FORSCHUNGS C MPUS öffentlich-privatepartnerschaft für Innovationen Funding: 15 years, 2 Mio /a Infrastructure and partner Joint research of industry and scientific institutions in a joint infrastructure CFK-Convention June 17, 2013 Slide 8
Open Hybrid LabFactory Open Hybrid LabFactory Integration of the expertise from scientific and industrial research in an "open 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 Setting of a public-private partnership, that meets future technical challenges in an open and versatile way. CFK-Convention June 17, 2013 Slide 9
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 Planning, Handling & Bonding Injection molding and organo sheets (sponsored by the state of Lower Saxony) Handling, Draping and Preassembly CFK-Convention June 17, 2013 Slide 10
Exemplary Process Chain in Open Hybrid LabFactory FRP semi finished products (metallic, FRP) Functional elements Fibres Sheet products Hybrid Component IWF topics in this process chain Automation and handling technology Multifunctional and flexible handling concepts Process control - concepts Mobile (autonomous) robots Hybrid-Press- and Tool-Technology Hybrid-Press Multipoint actuators Integrated cooling / heating Modular tool concepts Quelle: H+R Quelle: Siempelkamp CFK-Convention June 17, 2013 Slide 11
Research priorities Research Group Assembly and Production Automation Assembly Production Automation 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 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 Shape-memory alloys, Piezo crystals CFK-Convention June 17, 2013 Slide 12
Exemplary Process Chain in Open Hybrid LabFactory FRP semi finished products (metallic, 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 CFK-Convention June 17, 2013 Slide 13
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 CFK-Convention June 17, 2013 Slide 14
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 CFK-Convention June 17, 2013 Slide 15
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 CFK-Convention June 17, 2013 Slide 16
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 CFK-Convention June 17, 2013 Slide 17
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 CFK-Convention June 17, 2013 Slide 18
Application of FormHand 1. Gripping and Draping with FormHand Video 2. Draping with FormHand 3. FormHand as a Form Tool CFK-Convention June 17, 2013 Slide 19
Video: The FormHand Concept CFK-Convention June 17, 2013 Slide 20
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 CFK-Convention June 17, 2013 Slide 21
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 CFK-Convention June 17, 2013 Slide 22
Handling Technologies with integrated Functionality for the Production of Composite Components tool preform Mold Work piece 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 Form-Flexibility with integrated heating 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 CFK-Convention June 17, 2013 Slide 23
Innovative Handling Technology with Integration of Functions State-of-the-Technology: Vacuum-Gripping of limp textiles Innovation 1: Integration of heating devices into the gripper, combination with robotics Vacuum Gripper Vacuum Connection Innovation 2: Form-Flexible Gripping (self-adjusting gripping and draping) Integrated heating Reducing Process Time: Integration of Functions: Gripping, Draping and Heating Form-Flexibility with integrated heating CFK-Convention June 17, 2013 Slide 24
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) CFK-Convention June 17, 2013 Slide 25
FormHand in the preforming process These activities are carried out by the research partner ifs CFK-Convention June 17, 2013 Slide 26
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 CFK-Convention June 17, 2013 Slide 27
Institute of Machine Tools and Production Technology Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen Thank you for your attention! Form-flexible Handling Technology (FormHand) for Automation in RTM preforming 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
Institute of Machine Tools and Production Technology Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen Contact Information Dr.-Ing. A. Raatz: a.raatz@tu-braunschweig.de Dipl. Wirtsch.-Ing. C. Löchte: c.loechte@tu-braunschweig.de Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig