Automation plays a vital role in increasing the competitiveness of a company, especially in the context of Industry 4.0. In the production of large structures, in particular, the challenges lie in the small batch sizes and the large workpiece dimensions coupled with the large manufacturing tolerances of semi-finished products. When using robots in this environment, the cost of programming is a decisive factor in the use of robots.
For this reason, our experts are working on automatic programming of such systems. Our solutions are being successfully implemented in the maritime industry. Their special feature is that they are based on analysis of 3D sensor data and require no connection to a CAD/CAM system. In addition to programming, the hardware requirements for the use of robots in the maritime industry are often not a given. Therefore, the team is engaged in the development and realisation of application-specific handling systems and end-effectors for various applications. In this context, we pursue a variety of paths. Our range of solutions extends from the classic robot cell, through the application of commercially available systems in mobile robot cells, to the complete development and implementation of application and industry-specific large and heavy-duty robot systems. The use of mobile robot systems, which enable the application of our robot technologies in new industries such as agriculture, is becoming increasingly important. We work closely with the specialist departments of the institute on an interdisciplinary basis.
Development of a System for the Automated Planting of Frigo Seedlings
The project focuses on increasing the efficiency of strawberry frigo seedling cultivation in rack-based systems. To counter rising labor costs and the shortage of seasonal workers, the planting process is being analyzed and an automation concept developed. Expertise in the cultivation of strawberry frigo seedlings in rack systems is provided by the project partner Karls Markt OHG. Key requirements and parameters serve to define and automate the ideal process of planting a frigo strawberry plant into the substrate. The goal is to handle the organic plant seedlings and develop an automated solution for placing them into the substrate.
Development of an Automated Carrier System for Fastening Tools on Longitudinal Joints
For the construction of wind turbines using panel-based designs, individual panels are to be assembled into a tower structure. As hub heights continue to increase, conventional tower construction methods are becoming less economical. To simplify the joining of these elements, the fitter is only required to screw on and secure the joining component of the connection system from the inside of the tower. The connection systems themselves are to be automatically supplied and positioned from the outside of the tower.
To achieve this, an automation solution in the form of a bolt insertion robot has been developed. The robot autonomously traverses the connection line, detects the boreholes, and provides the necessary fastening elements to the fitter for assembly.
Development of Intelligent Welding Robots for Shipbuilding Applications
Special shipbuilding in Germany is characterized by small batch sizes and the use of various materials. One of the key steps in hull construction is welding. The objective of this research project is to develop a system for programming welding robots in shipbuilding, which automatically generates the required robot programs for welding based on 3D sensor data of the current components.
Potential analyses and feasibility studies for innovative product ideas as well as optimization of existing systems
Design and development of prototype systems (CAD design, structural optimization, design of electric drive systems, electrical engineering)
Simulation of complex kinematics and analysis of force effects (multibody simulations, FEM analysis)
Manufacturing, assembly, and commissioning of prototypes and test rigs
Systematic testing and execution of field trials
Implementation of application-specific control and automation software
Evaluation and visualization of measurement data