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.

© Fraunhofer IGP

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

Seedling Robot

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.

GreT

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.

IntRobAS

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.

Projects

Fertigung von Passrohrverbindungen
(Laufzeit '17-'18)
Konzept zur sensorgestützten Fertigung von Passrohrverbindungen
Ebersdorfer-Kogge / Astronomische Uhr Marienkirche
(Laufzeit '16-'17)
Modellfertigung der Ebersdorfer-Kogge und der astronomischen Uhr Marienkirche
MACH-FLEX-FORM
(Laufzeit '16-'17)
MACH-FLEX-FORM
AutoHot3D
(Laufzeit '16-'17)
Teilautomatisierter Herstellungsprozess für 3D-FKV-Heißpressbauteile – AutoHot3D
MoZzeR
(Laufzeit '15-'18)
Mobile Zerlegungszelle für Rotorblätter – MoZzeR
Palettierung – INSTAMAK
(Laufzeit '15-'17)
Palettierung – INSTAMAK
Kantenrunden von Flachbauteilen
(Laufzeit '15-'16)
Automatisiertes Kantenrunden von Flachbauteilen
Bohrroboter
(Laufzeit '15-'17)
Bohrroboter
Küstenabbruchmodell Darßer Ort
(Laufzeit '15)
Küstenabbruchmodell Darßer Ort
Endeffektor
(Laufzeit '14-'15)
Endeffektor zum hochgenauen robotergestützten Bohren auf Freiformflächen
Rohrknoten
(Laufzeit '13-'17)
Automatisiertes Schneiden und Schweißen von Rohrknoten
Produktion von Mikropaneelen auf Grundlage von CAD-Daten
(Laufzeit '12-'13)
Entwicklung von Softwarekomponenten zur automatisierten Produktion von Mikropaneelen auf Grundlage von CAD-Daten
PASK
(Laufzeit '11-'12)
Übergroße Parallel-Abstell-Schiebe-Kipp-Fenster (PASK)
Stabkinematik Grossroboter IMG
(Laufzeit '10-'14)
Stabkinematik Grossroboter IMG
BleSo
(Laufzeit '10-'12)
Automatische Blechsortierung im Schiffbau
WEA-Gitterturm
(Laufzeit '10-'12)
Entwicklung eines Langzeit-Monitoringsystems für einen WEA-Gitterturm
Intelligenter 3-D-Schwerlastaufnehmer
(Laufzeit '09- '10)
Intelligenter 3-D-Schwerlastaufnehmer zur Gewicht- und Schwerpunktbestimmung von Großstrukturen
MEKAPRO
(Laufzeit '08-'11)
Mechanische Kantenbearbeitung von Profilbeschnitten im Schiffbau
PASS (Laufzeit '08-'09) Putzmeister Automatic Spraying System
Herstellung eines Weltozean-Globus für das Ozeaneum
(Laufzeit '08)
Herstellung eines Weltozean-Globus für das Ozeaneum in Stralsund
Entwicklung eines Ostseereliefs für das Ozeaneum
(Laufzeit '08)
Entwicklung eines Ostseereliefs für das Ozeaneum in Stralsund
System zur Masse- und Schwerpunktbestimmung
(Laufzeit: '07-'08)
System zur Masse- und Schwerpunktbestimmung von Sektionen
Dockmess
(Laufzeit: '07)
Laserbasiertes Positioniersystem für den Eindockvorgang - DockMess
Jack-Up
(Laufzeit: '07)
Bestimmung der Lagerlasten von Antriebswellen mittels teilautomatisierter sensorgestützter Jack-Up Methode
GEMAS
(Laufzeit: '05-'07)
Gewichtsmanagementsystem in der Unikatfertigung hochausgerüsteter Spezialschiffe - GEMAS
MaPos
(Laufzeit: '04-'07)
Optimale Montage des Antriebssystems von Schiffen - MaPos
Roboter-Baukasten
(Laufzeit: '04-'06)
Entwicklung eines Roboter-Baukastensystems für spezielle Handhabungsaufgaben in der Kunststoffindustrie
ROPROBIL
(Laufzeit: '02-'05)
Programmierung von Schweißrobotern durch Bilderfassung
Virkom
(Laufzeit:'02-'05)
Kompetenzverbund für innovative Produktionstechniken

Services

  • 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