Overhead presentation. Based on their outstanding mechanical properties and low density, carbon fibre reinforced polymers (CFRP) offer a high potential for structural lightweight design. To use the maximum performance of CFRP, the structural design has to be adapted to the anisotropic mechanical properties. Additionally, it still remains a challenge to economically produce the components. Striving for a cadence of 40 "near-black" aircraft per year for the next generation passenger aircraft, the number of components adds up to hundred thousands. Thus, manufacture with a high degree of manual work and the classical end of line quality assurance is not adequate for economic production of CFRP aircraft components. A consequent shift towards automation, flexibility and high throughput of the production processes including process integrated quality assurance is the appropriate answer. For this, the German Aerospace Center (DLR) built up the Center for Lightweight Production Technology (ZLP) with sites in Augsburg and Stade, greatly supported by the governments of the German States Bavaria, Lower Saxony and by the German Federal Ministry of Economics and Energy (BMWi). The main research focus of the ZLP lies in the improvement of the floor-to-floor-efficiency of the production processes. To attain lay-up-rates above 100 kg/h, the ZLP follows two strategies: parallelized, robot-based fibre placement devices (ZLP Stade), and cooperating robots for the lay-up of large NCF half-wares (ZLP Augsburg). Supplementary research work yields for the robustness of the robotic systems and the mechatronic handling devices, which should assure the decrease of down-times. The focus of this presentation lies on the research work in Augsburg. Following the demand for a flexible, automated robot based production system with lay-up rates above 100 kg/h and a lay-up precision better than 1 mm an internationally unique robotic system had been built up in the last four years in Augsburg. Core of the new system is a system of five robots in hang-down configuration installed in a steel frame sized 19 x 29 m placed on concrete pillars. This hang-down configuration offers maximum flexibility for the placement of moulds of different size. As the robots drive from the upper frame into the moulds no reconfiguration of the robot placement and the related infrastructure is necessary. That opens new options of driving components of different geometry sequentially or in parallel through the production process. The benefit could be greatly reduced set-up time and the enhancement of flexibility, both yielding for reduced cost and time of production. As lay-up precision better than 1 mm is mandatory the ZLP Augsburg and the DLR Institute for Robotics and Mechatronics developed an active vibration and deflection compensation system that bases on a numerical model of the frame and the robot system, on an external optical guiding system and on the real time adjustment of the robot position. The consequence is a lay-up precision of today 0,4 mm yielding for 0,2 mm in the near future. Robots need "hands" to work with. Thus, a second mainstream of the ZLP Augsburg is to work on new mechatronic handling devices to precisely lay-up the textile CF half-wares. In cooperation with partners of industry and research the ZLP Augsburg works on robust and flexible, contour adaptive grippers and lay-up heads for e.g. CF or copper based anti-lighting foils. Finally these end-effectors are validated in the process chain. Today, quality assurance is an add-on process cycle, which therewith drives cost. To avoid this additional cycle and the jettison of failure containing parts at the end of the value chain, ZLP Augsburg works on a new process integrated QA system as well. Specific analysis modules located along the production chain and yielding from laser based fibre angle detection to thermography or fast ultra-sonic devices, aim for additional cost and cycle time reduction. All the technologies described are tested and validated within the complete CFRP production process chain in Augsburg.


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    Titel :

    Robotergestützte Produktionstechnologien für Composite-Bauteile


    Weitere Titelangaben:

    Robot based production technology for composite components


    Beteiligte:


    Erscheinungsdatum :

    2014


    Format / Umfang :

    23 Seiten, Bilder, Tabellen



    Medientyp :

    Aufsatz (Konferenz)


    Format :

    Datenträger


    Sprache :

    Deutsch






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