Skip to main content
SpringerLink
Log in

Investigation of an automated dry fiber preforming process for an aircraft fuselage demonstrator using collaborating robots

  • Original Paper
  • Published:
CEAS Aeronautical Journal Aims and scope Submit manuscript

Abstract

High-performance carbon fiber-reinforced plastics (CFRP) see a continuous growth of their share in structural weight. In particular, in Aerospace, this includes the production of large components, where the key issue of significant high costs remains persistent. The Center for Lightweight Production Technologies in Augsburg as a part of the German Aerospace Center (DLR) addresses this problem with solutions for process automation to increase repeatability, process robustness, and cost-efficiency. This paper presents an approach for automated preforming of large CFRP parts by means of collaborative robots. Investigations include process development for robotic handling of large-carbon fiber cut- pieces and validation on a full-scale demonstrator. The experimental verification is focused on a demonstrator geometry that represents a fuselage section of a typical short- to mid-range aircraft. The work is completed by a discussion about the challenges, solution approaches, and observations. The presented semi-automated preforming process with collaborating robots is an important intermediate step on the way to a fully automated production process for large Aerospace parts made of CFRP.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25

Similar content being viewed by others

References

  1. Ehrenstein, G.W.: Faserverbund-Kunststoffe: Werkstoffe-Verarbeitung-Eigenschaften. Carl Hanser Verlag, Munich (2006)

    Google Scholar 

  2. Gerngross, T., Nieberl, D.: Automated manufacturing of large, three-dimensional CFRP parts from dry textiles. CEAS Aeronaut. J. 7, 214–257 (2016). doi:10.1007/s13272-016-0184-5

  3. Gerngross, T., Krebs, F., Buchheim, A.: Automated production of large CFRP preforms: challenges and solutions along the process chain. Composites Manufacturing, Frankfurt (2012)

    Google Scholar 

  4. Schuster, A., Kuehnel, M., Kupke, M.: Automated preforming of curved thermoplastic organic sheets. SAMPE Europe Conference, Amiens (2015)

  5. Gerngross, T.: Automatisierung der Produktion von Faserverbundbauteilen in der Luftfahrt. Ingenieurspiegel Luftfahrt, pp. 50–52. Public Verlag, Bingen (2014)

  6. Gerngross, T., Schmidt, T., Krebs, F.: Herausforderungen für die Automation von robusten Produktionsprozessen für Faserverbundstrukturen. 1. Augsburger Produktionskolloquium, Augsburg (2011)

  7. Newell, G.C., Khodabandehloo, K.: Modelling flexible sheets for automatic handling and lay-up of composite components. Advanced Manufacturing and Automation Research Centre, University of Bristol (1994)

  8. Irvine, H.M.: Cable structure. Penerbit ITB, Indonesia (1988)

  9. Braun, G., Buchheim, A., Fischer, F., Gerngross, T.: Handgeführter Endeffektor für die automatisierte Handhabung von textilen Zuschnitten. Deutscher Luft- und Raumfahrtkongress, Stuttgart (2013)

    Google Scholar 

  10. Sener, D.: Handling von Faserhalbzeugen in der automatisierten CFK-Produktion. Studienarbeit, Institut für Bauweisen und Strukturtechnologie, DLR Stuttgart, Augsburg (2011)

  11. Larsen, L., Braun, G.: Entwurf und Test eines Saugsystems für das automatisierte Handling von Kohlefasergelegen. Institut für Bauweisen und Strukturtechnologie, DLR Stuttgart, Augsburg (2011)

  12. Braun, G., Gerngross, T.: Entwicklung eines Endeffektors für das Handling von Kohlefasergelegen. Institut für Bauweisen und Strukturtechnologie, DLR Stuttgart, Augsburg (2011)

  13. Kuka Systems GMBH: KUKA.RoboTeam 2.0. Augsburg (2013)

  14. Schuster, A.: Computer Vision für die CFK-Produktion: Autonomes Greifen von individuellen Preforms. Deutscher Luft- und Raumfahrtkongress, Augsburg (2014)

    Google Scholar 

  15. Schuster, A.: Autonomes System zur Herstellung von Organoblechen und Preforms. Dissertation, University Augsburg, Augsburg (2015)

  16. Krebs, F., Larsen, L., Braun, G., Dudenhausen, W.: Design of a Multifunctional Cell for Aerospace CFRP Production. 23rd International Conference on Flexible Automation & Intelligent Manufacturing, Porto (2013)

Download references

Acknowledgments

This work is a team effort and would not have been possible without manifold contributions from our industrial partner Kuka Systems GmbH and our colleagues at the DLR. In particular, we would like to thank Dr. A. Schuster, F. Krebs, and L. Larsen for their enduring help and input. Funding was provided by the City of Augsburg and the Federal State of Bavaria.

Author information

Authors and Affiliations

  1. Center for Lightweight Production Technology, Institute of Structures and Design, German Aerospace Center, Am Technologiezentrum 4, 86159, Augsburg, Germany

    Mona Eckardt, Andreas Buchheim & Tobias Gerngross

Authors
  1. Mona Eckardt
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Andreas Buchheim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tobias Gerngross
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mona Eckardt.

Additional information

This paper is based on a presentation at the German Aerospace Congress, September 16–18, 2014, Augsburg, Germany.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Eckardt, M., Buchheim, A. & Gerngross, T. Investigation of an automated dry fiber preforming process for an aircraft fuselage demonstrator using collaborating robots. CEAS Aeronaut J 7, 429–440 (2016). https://doi.org/10.1007/s13272-016-0199-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13272-016-0199-y

Keywords

Search

Navigation