slc-lab opening event - kuka

Specification for industrial robots in CFK-machining

www.kuka-robotics.com

SLC 2012 - HeverleeKUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 |

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



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



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



• 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



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



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



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



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



Industry – Arguments for new materials => New processes

Source: Airbus/EADS/PAG



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


Company PresentationKUKA Roboter GmbH | Sales | Wilfried Eberhardt | 26.04.2012 |

Process automationin aerospace and automotive

Today Future

Manual Industrialised

Industry – FRP Processes



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



KUKA today. Aerospace - fiber placement



Source: EADS/HerzogCFK plait

KUKA today. Aerospace / Automotive – Braiding



KUKA today. Aerospace - preforming

Picture/Courtesy: EADS IW



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



KUKA today. Aerospace/General Industry – Winding

Picture/Courtesy: MFTec

Pipe or tanks production in Aerospace or General industry



KUKA today. Space/Aerospace – Thermoplast winding

Picture/Courtesy: EADS IW Source: AFPT

MT Aerospace produce tanks foruse in Space orAerospace

Solution by AFPT



KUKA Systems - solution for thermoplast welding.Guarantee for high quality in complex processes

Source: KUKA Systems

CFRP bonding – Robotised solution for Thermoplast Matrix



KUKA today. Aerospace assembly - fastening

Source: EUROCOPTER / Brötje Automation

Source:Airbus MeaulteAlema Automation



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



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)



KUKA. Aerospace - inspection

Source: iPhoton

Source: GOM

Optical inspection

Laser Ultrasonic

Shearographie

Source: Dantec



KUKA. Aerospace MRO – inspection and (rapid) repair

Source: Lufthansa Technik

Customer Lufthansa Technik ask for ww solutions…



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



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

Source: KUKA / Siemens



Examples from process validation Automotive

Source: ZLP Nord-Süd, DLR

Today Future

Manual Industrialised



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



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



KUKA today. Technology partnerships and organisation



Examples from process validation for airplane production

Source: ZLP Nord/Süd, DLR



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



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



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



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



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



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



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 |

Together to the next level…

Thank you for yourattention