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Institute of Machine Tools and Production Technology

Dr.-Ing. Annika Raatz, Dipl. Wirtsch.-Ing. Christian Löchte IWF – Technische Universität Braunschweig CFK-Convention 2013 – Stade

Form-flexible Handling Technology (FormHand) for Automation in RTM preforming

Institut für Werkzeugmaschinen und Fertigungstechnik

Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming

CFK-Convention | June 17, 2013 | Slide 2

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




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

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6%

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[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%).

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) ca. 80 students





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





Open Hybrid LabFactory

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

Battery LabFactory Braunschweig




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


Partnerschaft

C MPUSöffentlich-private

FORSCHUNGS

für Innovationen

Funding: 15 years, 2 Mio€/a





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

LabFactory

“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 LabFactory

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





Hybrid Component


„Hybrid-Press“ Multipoint actuators Integrated cooling / heating Modular tool concepts

Quelle: Siempelkamp

Hybrid-Press- and Tool-Technology

Multifunctional and flexible handling concepts Process control - concepts

Mobile (autonomous) robots

Quelle: H+R

Automation and handling technology

IWF topics in this process chain




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 Shape-memory alloys, Piezo crystals





Hybrid Component


Multifunctional and flexible handling concepts Process control - concepts

Mobile (autonomous) robots

Quelle: H+R

Automation and handling technology

RG Assembly and Production Automation topics in this process chain

New handling concepts are requiered




Agenda






Summary and Outlook




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

Preforming attracts many research activities




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




1. Gripping and Draping with FormHand

Application of FormHand

Video

2. Draping with FormHand

3. FormHand as a Form Tool




Video: The FormHand Concept




Agenda






Summary and Outlook




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 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

Form-Flexibility with integrated heating




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 Functions: Gripping, Draping and Heating




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

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



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: [email protected]

Form-flexible Handling Technology (FormHand) for Automation in RTM preforming

Thank you for your attention!



Dr.-Ing. A. Raatz: [email protected] Dipl. Wirtsch.-Ing. C. Löchte: [email protected]

Technische Universität Braunschweig Institut für Werkzeugmaschinen und Fertigungstechnik

Langer Kamp 19b 38106 Braunschweig

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