2. 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
3. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 3 www.kuka-robotics.com
4. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 4 www.kuka-robotics.com
5. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 5 www.kuka-robotics.com
7. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 7 www.kuka-robotics.com
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
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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 8 www.kuka-robotics.com
9. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 9 www.kuka-robotics.com
10. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 10 www.kuka-robotics.com
11. Industry – Arguments for new materials => New processes
Source: Airbus/EADS/PAG
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KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 11 www.kuka-robotics.com
12. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 12 www.kuka-robotics.com
13. 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
14. 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
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KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 14 www.kuka-robotics.com
15. KUKA today. Aerospace - fiber placement
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KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 15 www.kuka-robotics.com
17. KUKA today. Aerospace - preforming
Picture/Courtesy:
EADS IW
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 17 www.kuka-robotics.com
18. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 18 www.kuka-robotics.com
19. KUKA today. Aerospace/General Industry – Winding
Pipe or tanks
production in
Aerospace or
General industry
Picture/Courtesy: MFTec
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 19 www.kuka-robotics.com
20. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 20 www.kuka-robotics.com
21. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 21 www.kuka-robotics.com
22. KUKA today. Aerospace assembly - fastening
Source: EUROCOPTER / Brötje Automation
Source:
Airbus Meaulte
Alema Automation
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 22 www.kuka-robotics.com
23. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 23 www.kuka-robotics.com
24. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 24 www.kuka-robotics.com
26. KUKA. Aerospace MRO – inspection and (rapid) repair
Customer Lufthansa Technik ask for ww solutions…
Source: Lufthansa Technik
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 26 www.kuka-robotics.com
27. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 27 www.kuka-robotics.com
28. KUKA today. X-Ray Healt care or somewhere else (industry)
Source: KUKA / Siemens
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 28 www.kuka-robotics.com
29. Today Future
Manual Industrialised
Examples from process
validation Automotive
Source: ZLP Nord-Süd, DLR
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 29 www.kuka-robotics.com
30. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 30 www.kuka-robotics.com
31. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 31 www.kuka-robotics.com
32. KUKA today. Technology partnerships and organisation
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 32 www.kuka-robotics.com
33. Examples from process validation for airplane production
Source: ZLP Nord/Süd, DLR
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 33 www.kuka-robotics.com
34. 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 Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 34 www.kuka-robotics.com
35. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 35 www.kuka-robotics.com
37. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 37 www.kuka-robotics.com
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
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 38 www.kuka-robotics.com
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 turning
materials station
changing of the whole tool possible
for using different spindle types or
switching between milling and
grinding
SLC 2012 - Heverlee
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 39 www.kuka-robotics.com
40. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 40 www.kuka-robotics.com
41. 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
KUKA Roboter GmbH | Key Technology | Otto Kellenberger | 26.04.2012 | Page 41 www.kuka-robotics.com
42. 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