Cyber-Physical Prefabrication Platform for Fibre Composites

Research Project 14-1 (RP 14-1)

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)
Timo König (ISW)
Christoph Zechmeister (ICD)

 

PEER-REVIEWED PUBLICATIONS

  1. 2022

    1. Gil Pérez, M., Zechmeister, C., Kannenberg, F., Mindermann, P., Balangé, L., Guo, Y., Hügle, S., Gienger, A., Forster, D., Bischoff, M., Tarín, C., Middendorf, P., Schwieger, V., Gresser, G. T., Menges, A., & Knippers, J. (2022). Computational co-design framework for coreless wound fibre-polymer composite structures. Journal of Computational Design and Engineering, 9(2), 310--329. https://doi.org/10.1093/jcde/qwab081
    2. Gil Pérez, M., Zechmeister, C., Menges, A., & Knippers, J. (2022). Coreless filament-wound structures: toward performative long-span and sustainable building systems. In S. Xue, J. Wu, & G. Sun (Eds.), Proceedings of IASS Annual Symposia 2022: Innovation, Sustainability and Legacy (Vol. 2022, pp. 3366–3376). International Association for Shell and Spatial Structures (IASS).
    3. Hügle, S., Genc, E., Dittmann, J., & Middendorf, P. (2022). Offline Robot-Path-Planning and Process Simulation for the Structural Analysis of Coreless Wound Fibre-Polymer Composite Structures. Key Engineering Materials, 926, 1445--1453. https://doi.org/10.4028/p-970esd
    4. Menges, A., Kannenberg, F., & Zechmeister, C. (2022). Computational co-design of fibrous architecture. Architectural Intelligence, 1(1), 6--. https://doi.org/10.1007/s44223-022-00004-x
    5. Wolf, M., Kaiser, B., Hügle, S., Verl, A., & Middendorf, P. (2022). Data Model for Adaptive Robotic Construction in Architecture. Procedia CIRP, 107, 1035–1040. https://doi.org/10.1016/j.procir.2022.05.104
  2. 2021

    1. Bodea, S., Mindermann, P., Gresser, G. T., & Menges, A. (2021). Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction. 3D Printing and Additive Manufacturing. https://doi.org/10.1089/3dp.2020.0346
    2. Bodea, S., Zechmeister, C., Dambrosio, N., Dörstelmann, M., & Menges, A. (2021). Robotic coreless filament winding for hyperboloid tubular composite components in construction. Automation in Construction, 126, 103649. https://doi.org/10.1016/j.autcon.2021.103649
    3. Ellwein, C., Reichle, A., Herschel, M., & Verl, A. (2021). Integrative data processing for cyber-physical off-site and on-site construction promoting co-design. Procedia CIRP, 100, 451–456. https://doi.org/10.1016/j.procir.2021.05.103
  3. 2020

    1. Wolf, M., Elser, A., Riedel, O., & Verl, A. (2020). A software architecture for a multi-axis additive manufacturing path-planning tool. Procedia CIRP, 88. https://doi.org/10.1016/j.procir.2020.05.075
  4. 2019

    1. Dambrosio, N., Zechmeister, C., Bodea, S., Koslowski, V., Gil Pérez, M., Rongen, B., Knippers, J., & Menges, A. (2019). Buga Fibre Pavilion: Towards an architectural application of novel  fiber composite building systems. In K. Bieg, D. Briscoe, & C. Odom (Eds.), Acadia 2019: Ubiquity and Autonomy, proceedings of the 39th Annual Conference of the Association for Computer Aided Design in Architecture, Texas (pp. 140--149). Acadia Publishing Company.
    2. Zechmeister, C., Bodea, S., Dambrosio, N., & Menges, A. (2019). Design for Long-Span Core-Less Wound, Structural Composite Building Elements. Impact: Design With All Senses Proceedings of the Design Modelling Symposium 2019, 401--415. https://doi.org/10.1007/978-3-030-29829-6 32

OTHER PUBLICATIONS

    DATA SETS

        

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