Cyber-Physical Prefabrication Platform for Fibre Composites

Research Project 14 (RP 14)

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

The goal of this project is to conceptualize and develop a reliable and fast cyber-physical prefabrication system (CPPS) that enables the fabrication of multifunctional, multi-scale load-adapted fibre composite material by utilizing collaborating robots.

Part of the CPPS is a new fibre handling technology, which exceeds the capabilities of the established fibre placement methods. Embedded sensors enable detailed monitoring of the process and material state and thus enable a sophisticated process control, online path-adaptation and building of a digital twin of the part. The digital twin enables the verification of the part’s structural integrity. An additional goal of this project  is to derive paths for the robots from a given part-structure. The challenges here are mainly rooted in 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 a lot more complex, requiring a sophisticated collision avoidance, kinematic redundancy resolution and detailed fabrication simulation.

Finally, in order to enable process control, digital twin construction and path-planning, a new method for process modelling is developed, in which 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)
Jörg Dittmann (IFB)
Sebastian Hügle (IFB)
Tobias Schwinn (ICD)
Marko Szcesny (IBB)
Martin Wolf (ISW)
Christoph Zechmeister (ICD)



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