Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen 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
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Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 3
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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1%
2%
3%
4%
5%
6%
7%
8%
Ante
il am
BIP
[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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 4
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 5
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 Production Technology
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 6
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 7
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 8
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 LabFactory
Partnerschaft
C MPUSöffentlich-private
FORSCHUNGS
für Innovationen
Funding: 15 years, 2 Mio€/a
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 9
Open Hybrid LabFactory
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 14
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 15
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 16
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 17
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 18
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 19
1. Gripping and Draping with FormHand
Application of FormHand
Video
2. Draping with FormHand
3. FormHand as a Form Tool
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 20
Video: The FormHand Concept
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 21
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 22
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 23
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 24
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
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 25
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)
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 26
FormHand in the preforming process
These activities are carried out by the research partner ifs
Institut für Werkzeugmaschinen und Fertigungstechnik
Dr.-Ing. Annika Raatz | Form-flexible Handling Technology for Automation in RTM preforming
CFK-Convention | June 17, 2013 | Slide 27
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
Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
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) Contact: Annika Raatz, E-Mail: [email protected]
Form-flexible Handling Technology (FormHand) for Automation in RTM preforming
Thank you for your attention!
Platzhalter für Bild, Bild auf Titelfolie hinter das Logo einsetzen
Institute of Machine Tools and Production Technology