Fraunhofer Institute for Large Structures in Production Engineering IGP
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Automation Engineering
Work area
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.
Project overview
Fertigungssystem
Automated production of pipe connections
Adapter pipes and flexi pipes
The automatic production of flexible pipe joints would improve productivity and quality, especially in metalworking, machinery and shipbuilding. Most welding equipment for pipe joints targets a specified product range with always the same process conditions. For flexible pipe connections, however, a broader product spectrum is to be targeted. Since the products are one-offs, programming the weld is another challenge. Here, it is necessary to realise a fast and intuitive component integration into the robot programme. These requirements can be met with the help of a 6-axis robot in conjunction with a coupled workpiece manipulator and automatic programming of the production system with interfaces to the design system.
Project overview
Projects
Services
Handling technology
- Development and realisation of robots and special kinematics designed to customer specifications
- Development of application specific end-effectors and devices
Control and regulation technology
- Development of individual robot and crane controls
- Integration of electric drive systems
- Measuring and sensor technology solutions for industrial use
- Process data processing and machine learning
Programming / sensor data processing
- Automatic robot programming
- Tool calibration and referencing
- Adaptive robot control
Robot applications
- In the field of joining, forming and generative processes
- Concept development of robot cells including the safety concept
- Selection and integration of tools and sensor technology
- Support for realisation
Equipment
Robot
- KUKA KR5-2 arc HW welding robot with DKP400 dual-axis positioner
- MIG/MAG tandem welding system (Fronius)
- Machining and handling robot cell KUKA KR 240
- KUKA KR15 welding robot incl. sensors and peripherals (MIG/MAG single-wire welding system) in gantry design (workspace 4,000 x 4,200 x 1,500 mm) for cutting, welding and milling tests
- 2x industrial robot KUKA KR10 R900 with additional axes and Roboteam interfaces
Software
- ANSYS
- MSC ADAMS
- CATIA
- TIA Portal
- Beckhoff TwinCAT
- LabView
E-technology & robotics laboratory
- Technical centre with complete equipment and large test area
- Mechanical workshop
- DMG turn-mill centre LTX beta 1250 with counter spindle and 16-axis star turret
- Deckel Maho 5-axis universal milling machine DMU 100 mono block with 32 magazine positions
- Various mobile extraction units