SLC-Lab Opening Event - Kuka

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.de

SLC 2012 - Heverlee
KUKA 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 technology

SLC 2012 - Heverlee

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, …

Heidelberg

SLC 2012 - Heverlee

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 575

SLC 2012 - Heverlee

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

Rollout

SLC 2012 - Heverlee

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 µm

Source: peashooter/pixelio.de (o.l.), Jan Michels/AWI (u.l.), aes-europe.de (u.m.), Martin Deggerl/Mikronaut (u.r.)

SLC 2012 - Heverlee

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 penalties

SLC 2012 - Heverlee

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:
SMILEY

SLC 2012 - Heverlee

Industry – Arguments for new materials => New processes

Source: Airbus/EADS/PAG

SLC 2012 - Heverlee

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 IW
SLC 2012 - Heverlee

Today Future

Manual Industrialised
Industry – FRP Processes

Process automation
in aerospace and automotive
Company Presentation
KUKA 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
Prepregs
Fibers

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 today. Aerospace - fiber placement

SLC 2012 - Heverlee

KUKA today. Aerospace / Automotive – Braiding

Source: EADS/Herzog
CFK plait

SLC 2012 - Heverlee

KUKA today. Aerospace - preforming

Picture/Courtesy:
EADS IW

SLC 2012 - Heverlee

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 release

Picture/Courtesy: DLR – ZLP South/KUKA Systems

SLC 2012 - Heverlee

KUKA today. Aerospace/General Industry – Winding

Pipe or tanks
production in
Aerospace or
General industry

Picture/Courtesy: MFTec
SLC 2012 - Heverlee

KUKA today. Space/Aerospace – Thermoplast winding

MT Aerospace
produce tanks for
use in Space or
Aerospace

Solution by AFPT

Picture/Courtesy:
EADS IW Source: AFPT

SLC 2012 - Heverlee

CFRP bonding – Robotised solution for Thermoplast Matrix
KUKA Systems - solution for thermoplast welding.
Guarantee for high quality
in complex processes

SLC 2012 - Heverlee Source: KUKA Systems

KUKA today. Aerospace assembly - fastening
Source: EUROCOPTER / Brötje Automation

Source:
Airbus Meaulte
Alema Automation

SLC 2012 - Heverlee

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 / DMG

SLC 2012 - Heverlee accuracy field ≥ 0,1 mm

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 / Grenzebach
SLC 2012 - Heverlee

KUKA. Aerospace - inspection
Optical inspection

Source: GOM

Laser Ultrasonic
Shearographie Source: iPhoton

Source: Dantec

SLC 2012 - Heverlee

KUKA. Aerospace MRO – inspection and (rapid) repair
Customer Lufthansa Technik ask for ww solutions…

Source: Lufthansa Technik

SLC 2012 - Heverlee

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 - Heverlee

KUKA today. X-Ray Healt care or somewhere else (industry)

Source: KUKA / Siemens

SLC 2012 - Heverlee

Today Future

Manual Industrialised

Examples from process
validation Automotive
Source: ZLP Nord-Süd, DLR

SLC 2012 - Heverlee

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) plate

SLC 2012 - Heverlee

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 pipes

SLC 2012 - Heverlee

KUKA today. Technology partnerships and organisation

SLC 2012 - Heverlee

Examples from process validation for airplane production

Source: ZLP Nord/Süd, DLR

SLC 2012 - Heverlee

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 Pro

Enginneering of FRP processes is KUKA CNC KUKA CNC
more important then metal processing Vision Tech Vision Tech

Prof. Ralf Cuntze, CCeV, Augsburg Plast Tech Plast Tech Plast Tech
Glue Tech
Safe Robot
SLC 2012 - Heverlee

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 industry

SLC 2012 - Heverlee

flexible robotic milling cells for cutting
composite 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 part

SLC 2012 - Heverlee

Robotized milling cells
Demands 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

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
grinding

SLC 2012 - Heverlee

New waste concept / Special tooling

Integrated 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 change

PCD 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

Benchmark for e-mobility

KUKA Quantec 300
KUKA CNC controler
Spindle 12 KW
RTM Parts, 3D
PCD tool
22000 rpm
12 m/min

SLC 2012 - Heverlee

Thank you for your
attention

Together to the next level…

JEC Europe 2012
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 42

SLC-Lab Opening Event - Kuka

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