Cyber-Physical Prefabrication Platform for Fibre Composites

Research Project 14-1 (RP 14-1)

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ADDITIVE CYBER-PHYSICAL PREFABRICATION PLATFORM FOR MULTIFUNC-TIONAL, MULTI-SCALE LOAD-ADAPTED FIBRE COMPOSITE BUILDING ELEMENTS INCLUDING FABRICATION SIMULATION AND DIGITAL TWIN

The aim of this project is to conceptualise and develop a reliable and fast cyber-physical prefabrication system (CPPS) that enables the fabrication of multifunctional, multi-scale load-adapted fibre composite materials using collaborating robots.

Part of the CPPS is a new fibre handling technology that exceeds the capabilities of the established fibre placement methods. Embedded sensors provide detailed process and material state monitoring, enabling a sophisticated process control, online path-adaptation and the creation of a digital twin of the part. The digital twin allows the structural integrity of the part to be verified. An additional goal of this project is to derive robot paths from a given part structure. The challenges here are mainly due to the complexity of the CPPS, which allows the simultaneous movement of multiple fibre handling systems, multiple robots and the part itself. In comparison to established path-planning approaches, path-planning becomes much more complex, requiring a sophisticated collision avoidance, kinematic redundancy resolution and detailed fabrication simulation. Finally, a new method for process modelling is developed to enable process control, digital twin construction and path planning, where a good trade-off between accuracy and speed needs to be implemented.

 

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. Alexander Verl
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW), University of Stuttgart
Prof. Achim Menges
Institute for Computational Design and Construction (ICD), University of Stuttgart
Prof. Dr.-Ing. Peter Middendorf
Institute of Aircraft Design (IFB), University of Stuttgart

TEAM

Dr.-Ing. Stefan Carosella (IFB)
Dr.-Ing. Armin Lechler (ISW)
Dr.-Ing. Tobias Schwinn (ICD)
Dr.-Ing. Christoph Zechmeister (ICD)
Jörg Dittmann (IFB)
Sebastian Hügle (IFB)
Marko Szcesny (IBB)
Martin Wolf (ISW)
Timo König (ISW)

 

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