wbk Institute of Production Science - IPT Development of a new gripper and sensors to improve handling Cutting Magazine Stack Preforming Separation Multi-layer handling Preform handling

www.wbk.kit.edu KIT – University of the State of Baden-Wuerttemberg and

National Research Center of the Helmholtz Association

wbk Institute of Production Science


Prof. Dr.-Ing. Jürgen Fleischer

Parque Tecnológico de São José dos Campos – São Paulo – Brasil: 20/05/2014

Lightweight Manufacturing at wbk

23.05.2014 2 © wbk Institute of Production Science

Prof. Dr.-Ing. J. Fleischer, Prof. Dr.-Ing. G. Lanza, Prof. Dr.-Ing. habil. V. Schulze

Development of production technologies for new materials,

processes and construction methods with a high potential for

lightweight construction

Quality management Joining technologies

Process chains Finishing

Process chains

Prototypes

Assembly systems

Lightweight Production

Strategies for

processing

Clamp technologies

Correlation

Measuring strategy

Measuring technologie

Hybridization

Joining elements

Joining process

wbk Institut für Produktionstechnik wbk Institute of Production Science



Presentation structure

Lightweight Manufacturing

Metallic

FRP

Hybrid

Production applications




Space-Frame-Structure made of aluminum

Guiding and cutting

Profile

extrusion Processing

Automated

assembly

Inline quality

management

Positioning

Metallic Lightweight Manufacturing

Development of technologies for automated and flexible series productions of

lightweight frames made of aluminum

Profile

extrusion



Leichtbaufertigung am wbk: Metall

1

Prepositioning

2

Detection of

the markers

3 Planning of

the

intermediate

steps

4

Execute step

(correction)

5 Target achieved? No

6

End

Yes


Automated assembly - Positioning

Goal: Joining gap smaller 0,1 mm

Compensation of:

Geometry errors

Deformation by gravity

Position error (robot)

Deviation of gripping position



Automated assembly - Correction steps

4 I Lösung für die vorrichtungsfreie Anordnung

Correction steps in two parts

Correction of all orientations and two translations

Translational motion perpendicular to joining surface

Control measurement after each correction step

Step 1

Correction:

3 orientations

2 translations

Step 2 Finish

Correction: 1 translation

Correction: End of the correction

process




Generating mark with laser

Stereo camera system to detect the mark and calculate the position

Industrial robots to manipulated the position

Program to calculate the corrections

5 I Umsetzung und Validierung

Stereo camera system

aM bM

dK = 1,5/2/3/4 mm

aM = 10 mm

bM = 6 mm

Mark


Automated assembly - Detection of the markers

Overview Real mark



Automated assembly for Aluminum-Space-Frame-Structure





Metallic

FRP

Hybrid






FRP Lightweight Manufacturing

RTM Overview - Handling

Handhabung und Qualitätssicherung Handling and quality management

Infiltration Finishing Preforming

Textile Prefom Product

The Resin-Transfer-Molding process (RTM) offers great potential in the

production of FRP components in large numbers because a high degree of

automation is possible

Textile engineering Infiltration Textile engineering



Major challenge: Linkage of the different RTM process steps

Characterization of existing grippers

Development of a new gripper and sensors to improve handling

Cutting Preforming Magazine Stack

Separation Multi-layer handling Preform

handling

RTM Handling

Critical linkage steps RTM process

Electrostatic

gripper

Freeze

gripper

Coanda

gripper

Bernoulli

gripper

Needle

gripper

FRP Lightweight Manufacturing FRP Lightweight Manufacturing



RTM Handling IGrip

Coanda gripper with a electrical resistance sensor

Sensor with two electrodes

Measuring the electrical resistance

Calculation of the holding force

Coanda gripper with sensor

1 - Inner electrode

2 - Outer electrode

3 - Suction surface

4 - Attachment

5 - Standard „Composite

Gripper“ [Schmalz]


FA

RCont

Force [N] Electrical resistance [Ω/10]



RTM Handling IGrip advantages

Compensation of dynamic, normal and/or lateral forces

Saving compressed air (up to 70%)

Reliable automatic separation

Noise reduction and cheap sensor


Regelung der Haltekraft Control of the holding force



Finishing


RTM Overview - Preforming

Preforming

Handling and quality management

Infiltration Preforming

Textile Prefom Product

Textile engineering Infiltration Textile engineering



Preforming – Strategies

Strategies for Prefoming

Subpreform

(piecewise)

Fullply

(entire element)

Preforming

in stacks

Preforming

in layers

Cycle time

Quality

Cycle time

Quality

Cycle time

Quality

Cycle time

Quality

Resin-Transfer-Molding

Strategy depends on cycle time, quality and complexity of the components

Draping and fixation of textile semi-finished products requires customized

production strategy




Local sequential Preforming in layers

Processing of large areas by roll tool with integrated fixation

Additional fixation of the geometry of the Preform edges by edge tool

Reduction of wrinkles with tendering frame

End effector for local Preforming




Global Preforming in layers

End effector for global Preforming


End effector for global Preforming 2.5D-Geometries



Production of the Subpreform in one step by using a stack of textile products

Allows an optimization of the cycle time by producing locally limited

geometries

Production of several Subpreforms

Assembling to one Preform

Flexible preforming station

Global subprefoming in stacks





Metallic

FRP

Hybrid






Political and social guidelines

European regulations to reduce CO2 emission from vehicles

High-Tech Strategy of the Federal Government "Climate and Energy" and

"Mobility"

Objective

Increase the energy efficiency of vehicles through innovative Lightweight Manufacturing

Combining different materials by hybrid Lightweight Manufacturing

Porsche

Motivation Hybrid Lightweight Manufacturing



Fundamental research about material, methods and production

Concatenation of the fields of expertise, transfer to industrial application and

identification of innovative products

Developing the scientific basis and transfer to

industrial application

Material model

Part dimensioning

Simulation

Methods

Characterization

Test methods

Materials:

Process

Automation

Quality management

Production:

www.SPP-1712-hybrider-leichtbau.de

Hybrid Lightweight Manufacturing

Consideration of all aspects of Lightweight Manufacturing



1. Basic research of intrinsic hybridization based on Inserts with punctual force transmission

to the foot plate

2. Geometry adaptation and transfer of the developed knowledge for complex structures

Increasing the complexity and degree of hybridization

Optimization of load application (process, geometry, surface)

Start SPP phase 1:

Punctual

force transmission

SPP phase 2:

Load-bearing hybrid

structure

End SPP phase 1:

Linear

force transmission

Metallic component serves to transmit force to

the part itself

Metallic component

serves as a supporting

structure


From Insert to load-bearing hybrid structure



Development of new Insert-Technologies by design optimization

Development of automated processes to integrate the Inserts into the fiber

material

Consideration of the requirements for series production


Inserts-Technologies



No disruption of the fibers

Baseplate Threaded bushing

Large-area load

transmission F

No need to drill


Embedded force transmission elements (called inserts) offer the ability of material-

specific force transmission in FRP components

Inserts-Technologies benefits



Optical inspection of test plates with glass fibers

Polished cut images

→ Complete infiltration possible with used RTM mold and process parameters

Embedding of inserts in the RTM process


Infiltration results

Preform Infiltration Product



Inserts-Technologies example

Example of design optimization

Before: Flat baseplate After: Optimized baseplate

Result:

Improved tensile

force

Improved bending

moment





Automated integration of Inserts

Design of a machine technology for the automated integration and

fixation of inserts

Handling of the inserts

Fixation of the inserts

Sliding the upper plies on top

Draping of Preforms with Inserts

An automation of this process should be possible and will be

investigated in following studies



Shafts and profiles by centrifugation

Leichtbaufertigung am wbk

Impregnation of the fibers with the matrix by rotating the tool at high speed

Additional spin core enable the production of non-circular hollow structures

and thus a fiber equitable power transfer to metals

Example Centrifugation process

Tool

Fiber Matrix Impregnation:

Weight < Centrifugal force

Curing of

the matrix

Tool standing Rotation

above minimum speed

Curing




With core

Without core

A

Core

A

A-A

Result:

Improved spread of matrix material by using a core

Matrix material

only at the edges

Matrix material

everywhere

Centrifugation with core




Centrifugation challenges

Al

CFK

Product

Air!

Solution: Ventilation holes

1. Design of Experiments: Reducing the

number of tests

2. Preparation of samples with different

ventilation holes

3. Analysis by computed tomography

(CT)

Goal: No entrapped air but only a small

number of ventilation holes





Upcoming projects - HyPro

Increasing efficiency and productivity of the RTM process for the manufacture

of hybrid components

Project goal Project start

Prototypes and demonstrator

Validation Project end

Process

Basic scientific study of individual aspects of the RTM process

Tool technology Inserts Preforming

With long fibers

Integration of

inserts and

continuous fibers

in preform

Geometry

optimization

Surface

optimization

Sealing concepts

Increase process

reliability



HyPro: Development of new technologies for the RTM-Process to

increase the efficiency and productivity of the production of hybrid

components: Demonstrator requirements


Part for automotive application

Possibility to use Fiberblow-Technology

Necessary to use Inserts

Possibility to reinforce the component with continuous fibers

Suitable for RTM-Process

Demonstrator requirements





Metallic

FRP

Hybrid






Goal

Development of a concept to adjust the eigenfrequency with a machine

component made of CFRP

Design of a bearing chamber design and a topology-optimized structure

Development of filling strategies for optimal filling of the component

Possibility to avoid rattling

Adjusting the process Adjusting the machine

Reduce cutting

depth

Reduce cutting

speed

Reduce

RPM Change Tool

Adjusting stiffness Damper

Higher machine

mass

𝜔 =𝑐

𝑚

Production Applications

Adjusting of the eigenfrequency: Motivation and Goal

Hybrid Lightweight Manufacturing Production Applications



CFRP allows a weight variable machine component with a lower mass than

comparable steel variants

Adjustment of the eigenfrequency by pumping the liquid in the chambers

Relation of mass slides / Fluid cheaper with CFRP

CFRP

High rigidity in comparison to

the density

Lightweight component

with high stiffness

High material damping

Fluid to adjust mass

Fluid allows adjustment of

the natural eigenfrequency

𝜔 =𝑐

𝑚 Slide with

chambers

Fluid

Tank

Pump

Adaptable machine slide: Idea




The tool slide made out of CFRP enables flexible adjustment of the

eigenfrequency (15%) by means of adding pumpable masses in the chamber

system

Solution allows higher machining performance by a simple mass adaption of

the machine slide

functional principle

demonstrator characterization

Hybrid Lightweight Manufacturing Production Applications

Adaptable machine slide: Solution and Demonstrator



ProLeMo: Production technologies for efficient lightweight motors for

electric vehicles – Motivation and Goal

Reduction of moment of inertia and total

mass

Product

Keep production costs low by flexibility

and a high quantities flexibility

Process

The aim of the project is the development of lightweight technologies for electric

powertrains as well as the development of the necessary machinery

Use of lightweight materials

in motor-housing and stator

Aluminum-winding

Use of lightweight

materials in rotor

Use of soft magnetic

composites for magnetic

active components

Dynamics

Moments of inertia

Weight

Efficiency




Idea

Identification of weight distribution in the electric motor

Finding the savings potential

Designing a technology matrix with alternative concepts for

shaft, rotor, stator and housing

Evaluation of concepts and selection

Method

Construction of lightweight components and

process technology for the production

Construction of a lightweight rotor with lightweight

shaft

Development of an efficient cooling system in the

stator

Testing and validation of the components

ProLeMo: Production technologies for efficient lightweight motors for electric

vehicles – Idea and method




Laufzeit: 1.1.2013 bis 31.12.2015

Fördervolumen: ca. 1,7 Mio. €

Gesamtvolumen: ca. 3,3 Mio €

ProLeMo: Production technologies for efficient lightweight motors for electric

vehicles – Project partners




Prof. Dr.-Ing. Jürgen Fleischer Management Board

Machines, Equipment and Process Automation

Karlsruhe Institut of Technology (KIT)

wbk Institut of Production Science

Kaiserstraße 12 Tel.: +49 (0) 721 608 44009 [email protected]

76131 Karlsruhe Fax: +49 (0) 721 608 45005 http://www.wbk.kit.edu


Documents

wbk Institute of Production Science - IPT Development of a new gripper and sensors to improve handling Cutting Magazine Stack Preforming Separation Multi-layer handling Preform handling