SLC-Lab Opening Event - Kuka
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SLC-Lab Opening Event - Kuka

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Presentation of Kuka during the SLC-Lab Opening event - 26/4/2012

Presentation of Kuka during the SLC-Lab Opening event - 26/4/2012

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SLC-Lab Opening Event - Kuka SLC-Lab Opening Event - Kuka Presentation Transcript

  • Specification for industrial robots in CFK-machining
  • Always in the fore of development KUKA Robot Group Otto Kellenberger Aerospace Application Global Key Technology Manager KUKA Roboter GmbH Office Headquarter: Hery-Park 3000 D-86368 Gersthofen/Augsburg Tel.: +49(0)821/4533-3567 Mobile: +49(0)174/3460254 E-mail: ottokellenberger@kuka-roboter.deSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 2 www.kuka-robotics.com
  • Automation technology. Since 1898. KUKA. At the cutting edge of technology from the outset. The new product generation from KUKA – Automation becomes easy First open PC-based robot controller KUKA Famulus, the world’s first electrical 6-axis industrial robot KUKA revolutionizes the welding technology: KUKA delivers first multi-spot welding line to Volkswagen AG Foundation in Augsburg, Germany as an acetylene factory for lighting – subsequently for oxyacetylene welding and cutting technologySLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 3 www.kuka-robotics.com
  • KUKA Developments – Product & Services Portfolio Leight Weight Robot, platform, mobility navigation and sensoric Deveolpment of partly autonomous and mobile robots cooperating with human beeings Sections/Applications Products Robotics for final assembly Medical robots LWR service robotics Medical robots LWR Dual Arm Health Care LWR Mobile Service robotics youBot Entertainment Add-ons Vision, Navigaton, … HeidelbergSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 4 www.kuka-robotics.com
  • KUKA mobility – automated guided vehicles „omniMove“ • The omniMove® wheel consists of 2 rim disks and 8 resp. 9 spherical rollers. • The rollers are arranged in an angle of 45 evenly around the wheel. KoM UTV-2 KoM UTV-2 KoM UTV-2 KoM UTV-2 KoM UTV-2 E375 3000 E375 8000 E375 12000 E375 16000 E375 20000 • The complete wheel is propelled by an electrical or hydraulic motor unit and single drive-controlled. • The rollers are not driven but free-wheeling. • The wheel is not steered but KoM UTV-2 KoM UTV-2 KoM UTV-2 KoM UTV-2 KoM UTV-2 orientated in the main driving E575 7000 E575 15000 E575 25000 E575 35000 E575 45000 direction. omniMove wheel omniMove UTV with wheel diameter 575SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 5 www.kuka-robotics.com
  • Composite part manufacturing with Robots
  • Status Quo Process Industrialisation and production technologies are not availlable like requested (high flexible) Automated process flow required R&D must be validated for production Synergies (Plastic/Composites and Aerospace) for Automotive industry RolloutSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 7 www.kuka-robotics.com
  • Leithweight design – examples from the nature Leightweight material types of plastics that result from bonding two or more homogeneous materials with different material properties . composite plastics that specifically use fibrous materials to mechanically enhance the strength and elasticity of plastics. The nature as an example for Leightweight contructions/design Natural fibers as natural composites 20 µmSource: peashooter/pixelio.de (o.l.), Jan Michels/AWI (u.l.), aes-europe.de (u.m.), Martin Deggerl/Mikronaut (u.r.)SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 8 www.kuka-robotics.com
  • Industry – Arguments for Lightweight construction Emission Limits for CO2defined by ACEA and EU CO2 - tolerance value – regarding ACEA and EU CO2 limits (€/g CO2 /(km * vehicle)) CO2 Penalties CO2 cars emmission in EU(g/km) ACEA industry commitment Actual planing (difference to target) Possible penaltiesSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 9 www.kuka-robotics.com
  • Industry – Arguments for Lightweight construction CO2-Emissions [g/km] 190 Ø 165 g/km 170 150 Ø 130 g/km Ø EU target 130 110 100% Ø 95 g/km 90 85% 75% 100% „Phase-in“ 70 65% New cars ~ ~ 0 ~ ~ 2008 2010 2012 2014 2020 2009 2011 2013 2015 Leightweight and E-Mobility for CO2 reducing/targeting Souce: SMILEYSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 10 www.kuka-robotics.com
  • Industry – Arguments for new materials => New processes Source: Airbus/EADS/PAGSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 11 www.kuka-robotics.com
  • Industry – Arguments for new materials => New processes Crash Element McLaren SLR made of carbon fibre Source: Daimler/Mercedes Braiding of carbon fibre Stitching of carbon fibre Source: KUKA/EADS IWSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 12 www.kuka-robotics.com
  • Today Future Manual Industrialised Industry – FRP ProcessesProcess automationin aerospace and automotiveCompany PresentationKUKA Roboter GmbH | Sales | Wilfried Eberhardt | 26.04.2012 | Page 13 www.kuka-robotics.com
  • FRP Processing Process Drapping process Injection process SMC, GMT, Winding, Lamination, Press technique RTM, VARI LFI Pultrusion Autoclav Impreg- nation PrepregsFibers Rovings Impreg- (1D) nation Multi- Textil Textil 2D- Texti achsis 3D- Forming Process Semifinish Process semi Preform finish Weaving Braiding Stiching 3D- semi Knitting Felting finished Source: ETH Composites Technologien Knitting SLC 2012 - Heverlee KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 14 www.kuka-robotics.com
  • KUKA today. Aerospace - fiber placementSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 15 www.kuka-robotics.com
  • KUKA today. Aerospace / Automotive – Braiding Source: EADS/Herzog CFK plaitSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 16 www.kuka-robotics.com
  • KUKA today. Aerospace - preforming Picture/Courtesy: EADS IWSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 17 www.kuka-robotics.com
  • KUKA today. Aerospace – automated preforming with RoboTeam High volume textile preforming in large Aerospace structures: - pick-up (from cutter) with gripper - Material forms catenary curve - Positioning and activation thermoplast binder - Gripper 2 releasePicture/Courtesy: DLR – ZLP South/KUKA Systems SLC 2012 - Heverlee KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 18 www.kuka-robotics.com
  • KUKA today. Aerospace/General Industry – Winding Pipe or tanks production in Aerospace or General industry Picture/Courtesy: MFTecSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 19 www.kuka-robotics.com
  • KUKA today. Space/Aerospace – Thermoplast winding MT Aerospace produce tanks for use in Space or Aerospace Solution by AFPT Picture/Courtesy: EADS IW Source: AFPTSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 20 www.kuka-robotics.com
  • CFRP bonding – Robotised solution for Thermoplast Matrix KUKA Systems - solution for thermoplast welding. Guarantee for high quality in complex processesSLC 2012 - Heverlee Source: KUKA SystemsKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 21 www.kuka-robotics.com
  • KUKA today. Aerospace assembly - fastening Source: EUROCOPTER / Brötje Automation Source: Airbus Meaulte Alema AutomationSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 22 www.kuka-robotics.com
  • KUKA today. Aerospace / Automotive – CNC machining Source: DMG FIRST CNC-Robot in the market: - for G-Code programming - to bring virtual world closer to real world - for cooperation with classical CNC machines - for higher operator acceptance/robot undestanding - for high flexible machining in restricted Source: KUKA / DMGSLC 2012 - Heverlee accuracy field ≥ 0,1 mmKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 23 www.kuka-robotics.com
  • KUKA today. Friction Stir Welding Thermoplast - Aluminium application evaluation & supply of KR500 & system integration optimization DeltaN® FSW System of EADS (fix shoulder around rotating tool & many other value added Inventions) up to 15 KN force controled Source: KUKA / EADS IW / iwb / Airbus / GrenzebachSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 24 www.kuka-robotics.com
  • KUKA. Aerospace - inspection Optical inspection Source: GOM Laser Ultrasonic Shearographie Source: iPhoton Source: DantecSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 25 www.kuka-robotics.com
  • KUKA. Aerospace MRO – inspection and (rapid) repair Customer Lufthansa Technik ask for ww solutions… Source: Lufthansa TechnikSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 26 www.kuka-robotics.com
  • KUKA today. Aerospace – mobile systems Source: S-L-C-R / KUKA Mobile Plattform for flexible Production lines Pictures courtesy: AIRBUS Automated Tool or Mould changing Mobile machining centre (in the whole plant / facility) Etc.SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 27 www.kuka-robotics.com
  • KUKA today. X-Ray Healt care or somewhere else (industry) Source: KUKA / SiemensSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 28 www.kuka-robotics.com
  • Today Future Manual Industrialised Examples from process validation Automotive Source: ZLP Nord-Süd, DLRSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 29 www.kuka-robotics.com
  • KUKA today. Trends and ideas for processes - (1) - hybrids Integrated functions GFK/CFK for simetrical profiles Universitys R&D Source: KUKA /TELSONIC Source: Uni x, PA6.6 Form part CFRP (EP) plateSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 30 www.kuka-robotics.com
  • KUKA today. Trends and ideas for processes - (2) - hybrids Different ideas to generate automated and efficient RFP parts Souce: KUKA/ KM Automation Source: ROSENBERGER Bendet metal pipes Universitys are looking for projects for this processing. Insert of metal pipesSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 31 www.kuka-robotics.com
  • KUKA today. Technology partnerships and organisationSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 32 www.kuka-robotics.com
  • Examples from process validation for airplane production Source: ZLP Nord/Süd, DLRSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 33 www.kuka-robotics.com
  • Robotic Assisted Portfolio (Options & Technologies) Preliminary Process Processe on the Machine Downstream Process clamping stack cutting bonding spraying winding drapping cutting stiching SMC Technique Ablegen cutting (VA)RTM Technique Insert lay up Injection molding Etc. Cradles Weaving Spray form Technique inspection PUR / Foaming Depalettising Packaging Extrusion Technique Pre heat Pultrusion Drilling / Milling Etc. Layering painting cleaning Welding Preforming curing injection Painting Etc. Etc. Sim ProEnginneering of FRP processes is KUKA CNC KUKA CNCmore important then metal processing Vision Tech Vision TechProf. Ralf Cuntze, CCeV, Augsburg Plast Tech Plast Tech Plast Tech Glue Tech Safe Robot SLC 2012 - Heverlee KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 34 www.kuka-robotics.com
  • KUKA. Global innovation Intrinsic autonomous intelligence Novel level of multifunction. Bionic efficient design Synergies for automation in: - aerospace (>80% market) - automotive (market leader) - wind energy - general industrySLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 35 www.kuka-robotics.com
  • flexible robotic milling cells for cuttingcomposite parts
  • RTM – complete process flow for automotive delivery carbon fiber (mats, coils…) cutting fiber placement releasing resin agent hardener preparation of carbon fiber handling multi layer preforming container station RTM Tool mixing head press RTM metering machine handling parts milling cell finished partSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 37 www.kuka-robotics.com
  • Robotized milling cellsDemands for efficient robotized systems, specially for composite materials High stiffness Smooth movements High feed rates (actually up to 12m/min) Complete offline programming and optimisation Integrated measurement of tool length and automated controlling of milling tools (for example toolbrake) after each process Automatic detection of spindle TCP SLC 2012 - Heverlee KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 38 www.kuka-robotics.com
  • Robotic milling cells milling cells for composite materials best flexibility with 6 axis robots multiple robots possible per cell high speed tool-change spindle automatic tool-changing special exhaustion system, optimized for milling composite turning materials station changing of the whole tool possible for using different spindle types or switching between milling and grindingSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 39 www.kuka-robotics.com
  • New waste concept / Special toolingIntegrated spindle exhaust system Optimized exhaust geometry for reducing risks of collisions during 3D- processing Double walled design for processing abrasive materials (e.g. Fiber composites) Detachable exhaust nozzle to enable tool changePCD tool with 4 flutes, 20 degrees helix,push cut and pull cut version hexacut tool with 8 flutes feed-rates up to 12m/min feed-rates up to 6 m/min no de-lamination, no re-working specially for thin materials on the part and honeycomb structures SLC 2012 - Heverlee KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 40 www.kuka-robotics.com
  • Benchmark for e-mobility KUKA Quantec 300 KUKA CNC controler Spindle 12 KW RTM Parts, 3D PCD tool 22000 rpm 12 m/minSLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 41 www.kuka-robotics.com
  • Thank you for your attention Together to the next level…JEC Europe 2012KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 42