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Specification for industrial robots in CFK-machining
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 2
Otto Kellenberger
Aerospace ApplicationGlobal Key Technology Manager
KUKA Roboter GmbH
Office Headquarter:Hery-Park 3000D-86368 Gersthofen/AugsburgTel.: +49(0)821/4533-3567Mobile: +49(0)174/3460254E-mail: [email protected]
Always in the fore of development
KUKA Robot Group
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 3
KUKA. At the cutting edge of technology from the outset.
Foundation in Augsburg, Germany as an acetylene factory for lighting – subsequently for oxyacetylene welding and cutting technology
KUKA revolutionizes the welding technology: KUKA delivers first multi-spot welding line to Volkswagen AG
First open PC-based robot controller
The new product generation from KUKA – Automation becomes easy
Automation technology. Since 1898.
KUKA Famulus, the world’s firstelectrical 6-axis industrial robot
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 4
Leight Weight Robot, platform, mobility navigation and sensoric
Deveolpment of partly autonomous and mobile robots cooperating with human beeings
Sections/Applications
� Robotics for final assembly
� Medical robots
� Health Care
� Service robotics
� Entertainment
Products
� Medical robots
� LWR service robotics
� LWR Dual Arm
� LWR Mobile
� youBot
� Add-ons Vision, Navigaton, …
Heidelberg
KUKA Developments – Product & Services Portfolio
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 5
• The omniMove®
wheel consists of 2 rim disks and 8 resp. 9 spherical
rollers.
• The rollers are arranged in an angleof 45 evenly around the wheel.
• The complete wheel is propelled byan electrical or hydraulic motor unit
and single drive-controlled.
• The rollers are not driven butfree-wheeling.
• The wheel is not steered butorientated in the main driving
direction.
KoM UTV-2 E375 3000
KoM UTV-2 E375 8000
KoM UTV-2 E375 12000
KoM UTV-2 E375 16000
KoM UTV-2 E375 20000
KoM UTV-2 E575 7000
KoM UTV-2 E575 15000
KoM UTV-2 E575 25000
KoM UTV-2 E575 35000
KoM UTV-2 E575 45000
omniMove wheel omniMove UTV with wheel diameter 575
KUKA mobility – automated guided vehicles „omniMove“
Composite part manufacturing with Robots
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 7
Status Quo
Process Industrialisation and production technologiesare 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
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 8
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
Source: peashooter/pixelio.de (o.l.), Jan Michels/AWI (u.l.), aes-europe.de (u.m.), Martin Deggerl/Mikronaut (u.r.)
20 µm
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 9
Industry – Arguments for Lightweight construction
Emission Limits for CO2 – regarding ACEA and EU
CO2
CO2 cars emmission in EU(g/km)ACEA industry commitment
Actual planing (difference to target)Possible penalties
Pe
na
ltie
s
CO
2li
mit
s (
€/g
CO
2 /(
km
* v
eh
icle
))
CO2 - tolerance value defined by ACEA and EU
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 10
Industry – Arguments for Lightweight construction
20132014 20202012
20092010
20112008
2015
110
90
130
0
CO2-Emissions [g/km]
70
170
150
190Ø 165 g/km
Ø EU targetØ 130 g/km
Ø 95 g/km
„Phase-in“New cars
65%75%
85%
100%
100%
~~ ~ ~
Leightweight and E-Mobility for CO2 reducing/targeting
Souce: SMILEY
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 11
Industry – Arguments for new materials => New processes
Source: Airbus/EADS/PAG
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 12
Crash Element McLaren SLR made of carbon fibre
Braiding of carbon fibre Stitching of carbon fibre
Industry – Arguments for new materials => New processes
Source: Daimler/Mercedes
Source: KUKA/EADS IW
www.kuka-robotics.com
Company PresentationKUKA Roboter GmbH | Sales | Wilfried Eberhardt | 26.04.2012 | Page 13
Process automationin aerospace and automotive
Today Future
Manual Industrialised
Industry – FRP Processes
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 14
FRP Processing Process
� Stiching� Felting� Knitting
Injection processDrapping process
Impreg-nation
Impreg-nation
Texti Process
Textil Process
Forming
Rovings (1D)
Prepregs
3D-Preform
Multi-achsis semi finish
3D- semi finished
Textil 2D-Semifinish
� Weaving� Braiding� Knitting
Fib
ers
RTM, VARILamination,
AutoclavPress technique
Winding, Pultrusion
SMC, GMT,LFI
Source: ETH Composites Technologien
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 15
KUKA today. Aerospace - fiber placement
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 16
Source: EADS/HerzogCFK plait
KUKA today. Aerospace / Automotive – Braiding
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 17
KUKA today. Aerospace - preforming
Picture/Courtesy: EADS IW
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 18
Picture/Courtesy: DLR – ZLP South/KUKA Systems
High volume textile preforming in large Aerospace structures:
- pick-up (from cutter) withgripper
- Material forms catenary curve
- Positioning and activation thermoplast binder
- Gripper 2 release
KUKA today. Aerospace – automated preforming with RoboTeam
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 19
KUKA today. Aerospace/General Industry – Winding
Picture/Courtesy: MFTec
Pipe or tanks production in Aerospace or General industry
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 20
KUKA today. Space/Aerospace – Thermoplast winding
Picture/Courtesy: EADS IW Source: AFPT
MT Aerospace produce tanks foruse in Space orAerospace
Solution by AFPT
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 21
KUKA Systems - solution for thermoplast welding.Guarantee for high quality in complex processes
Source: KUKA Systems
CFRP bonding – Robotised solution for Thermoplast Matrix
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 22
KUKA today. Aerospace assembly - fastening
Source: EUROCOPTER / Brötje Automation
Source:Airbus MeaulteAlema Automation
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 23
KUKA today. Aerospace / Automotive – CNC machining
Source: KUKA / 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
accuracy field ≥ 0,1 mm
Source: DMG
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 24
KUKA today. Friction Stir Welding Thermoplast - Aluminium
supply of KR500 &optimization
evaluation &system integration
application
up to 15 KN force controledSource: KUKA / EADS IW / iwb / Airbus / Grenzebach
DeltaN® FSW System of
EADS
(fix shoulder around
rotating tool & many
other value added
Inventions)
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 25
KUKA. Aerospace - inspection
Source: iPhoton
Source: GOM
Optical inspection
Laser Ultrasonic
Shearographie
Source: Dantec
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 26
KUKA. Aerospace MRO – inspection and (rapid) repair
Source: Lufthansa Technik
Customer Lufthansa Technik ask for ww solutions…
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 27
Source: S-L-C-R / KUKA
Pictures courtesy: AIRBUS� Mobile Plattform for flexible Production lines
� Automated Tool or Mould changing
� Mobile machining centre (in the whole plant / facility)
� Etc.
KUKA today. Aerospace – mobile systems
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 28
KUKA today. X-Ray Healt care or somewhere else (industry)
Source: KUKA / Siemens
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 29
Examples from process validation Automotive
Source: ZLP Nord-Süd, DLR
Today Future
Manual Industrialised
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 30
Integrated functions GFK/CFK for simetrical profiles
Source: KUKA /TELSONIC
Source: Uni x, PA6.6 Form part CFRP (EP) plate
Universitys R&D
KUKA today. Trends and ideas for processes - (1) - hybrids
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 31
Bendet metal pipes
Insert of metal pipes
Universitys are looking for projects for this processing.
Source: ROSENBERGERSouce: KUKA/ KM Automation
Different ideas to generate automated and efficient RFP parts
KUKA today. Trends and ideas for processes - (2) - hybrids
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 32
KUKA today. Technology partnerships and organisation
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 33
Examples from process validation for airplane production
Source: ZLP Nord/Süd, DLR
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 34
Robotic Assisted Portfolio (Options & Technologies)
Safe Robot
Plast Tech
SMC Technique
(VA)RTM Technique
Injection molding
Spray form Technique
PUR / Foaming
Extrusion Technique
Pultrusion
Etc.
drappingspraying
painting
curing
stackclamping
injection
cleaning
cuttingEtc.
Ablegen
Cradles
inspection
Packaging
Drilling / Milling
Welding
Painting
Etc.
bonding
cutting
stiching
Insert lay up
Weaving
Depalettising
Pre heat
Layering
Preforming
Etc.
cutting
winding
Preliminary Process Processe on the Machine Downstream Process
KUKA CNC KUKA CNC
Vision Tech Vision Tech
Plast Tech Plast Tech
Glue Tech
Sim Pro
Enginneering of FRP processes is more important then metal processing
Prof. Ralf Cuntze, CCeV, Augsburg
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 35
KUKA. Global innovation
Novel level of multifunction.
Bionic efficient design
Intrinsic autonomous intelligence
Synergies for automation in: - aerospace (>80% market)- automotive (market leader) - wind energy - general industry
flexible robotic milling cells for cutting composite parts
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 37
RTM – complete process flow for automotive
container station
releasing agent
carbon fiber(mats, coils…)
hardenerresin
delivery
RTM metering machine
mixing head
press
preparation of carbon fiber
cutting fiber placement
preforming
handling parts
finished partmilling cell
RTM Tool
handling multi layer
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 38
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
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 39
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 materials
� changing of the whole tool possible for using different spindle types or switching between milling and grinding
turningstation
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 40
New waste concept / Special tooling
Integrated spindle exhaust system
Double walled design for processing abrasive materials (e.g. Fiber composites)
Optimized exhaust geometry for reducing risks of collisions during 3D-processing
Detachable exhaust nozzle to enable tool change
PCD tool with 4 flutes, 20 degrees helix, push cut and pull cut version
� feed-rates up to 12m/min
� no de-lamination, no re-workingon the part
hexacut tool with 8 flutes
� feed-rates up to 6 m/min
� specially for thin materialsand honeycomb structures
www.kuka-robotics.com
SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 41
Benchmark for e-mobility
� KUKA Quantec 300� KUKA CNC controler� Spindle 12 KW� RTM Parts, 3D� PCD tool
� 22000 rpm� 12 m/min
JEC Europe 2012KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 42
Together to the next level…
Thank you for yourattention