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High-precision handling processes are essential for various high-tech industries and are typically realized using specialized high precision robots. Articulated robots are rarely used for such tasks due to their low stiffness and accuracy stemming from their kinematic structure. This work presents a methodology for designing handling processes that maximise repeatability with articulated robots. By considering their kinematic structures' highly pose dependent properties as well as sensitivity to external disturbances in every step of the processes design, significantly improved repeatability can be achieved. The applicability of the new methodology is verified experimentally using the example of handling of large silicon dies. [ABSTRACT FROM AUTHOR]

Utilizing real-time position information of individual factory objects is a promising field of action in manufacturing systems. For realizing that, different types of real-time locating systems (RTLS) are available which differ according their inherent characteristics, performance and, thus, their feasibility for value adding manufacturing use cases. The paper introduces an innovative RTLS which utilizes optical AI enhanced sensors to detect and track objects. Detailed technical analyses also in comparison with established tag based ultra-wideband (UWB) RTLS underline the general feasibility and good performance. Finally, the capability profiles of those different RTLS technologies were brought together with the requirements of specific manufacturing use cases in order to derive favourable application fields. [ABSTRACT FROM AUTHOR]

For the in-mould assembly of functionally integrated structures, a proper bond strength development between the different components has to be ensured during the actual manufacturing step. Physically detailed models and simulations are able to compute a reliable bond strength distribution. However, these computations are very time consuming. In this contribution, a simulation based surrogate model for the in-mould assembly of thermoplastic composite structures is developed. It predicts the bond strength within seconds using data from process simulations combined with machine learning, achieving a remaining error of less than 5% compared to high-fidelity computations. [ABSTRACT FROM AUTHOR]

The combination of hot-stamped steels and fibre-reinforced thermoplastics (FRTP) offers great potential for lightweight design. The process steps of hot stamping and thermoforming for the manufacturing of such hybrid structures are usually carried out in two separate steps. After hot stamping, the blank has to be reheated for the application of FRTP in order to enable the bonding of FRTP to the blank. Process integration of the individual processes means that reheating of the blank during thermoforming is no longer necessary. Due to non-uniform contact conditions during hot stamping between blank and tool, an inhomogeneous temperature distribution in the blank occurs, which would lead to non-uniform bonding properties between blank and FRTP after thermoforming. The aim of this work is to determine this non-uniform contact and the resulting heat transfer by a numerical model. By segmenting the tool in the model, a possibility is shown to control the non-uniform contact and to achieve a homogeneous temperature distribution in the blank after hot stamping. Furthermore, the temperature adaptability of the used tool and the resulting temperature distribution in the blank is investigated. Finally, the manufactured structures are tested in a numerical three-point bending test in order to be able to make a statement about their performances. [ABSTRACT FROM AUTHOR]

Grasp planning for vacuum-based handling is typically based on prior knowledge and experience. The most adequate grasp positions are selected and distributed manually. The objective of this work is a design method for grasp optimization under consideration of the object-gripper-specific form fit properties to maximize the holding force. The grasp optimization is based on a constrained genetic algorithm which evaluates both an even part's mass distribution and the holding force each gripper can provide. The results indicate that the proposed design method provides feasible grasp configurations for a large variety of different shell-like parts whilst enabling potential energy savings. [ABSTRACT FROM AUTHOR]

The fast and precise automated assembly of limp components to large stacks is a technical challenge. For high voltage fuel cell stacks, hundreds of thin, limp and brittle parts must be stacked precisely. To ensure a robust and fast stacking process, a deviation compensation strategy is presented which allows for increased precision and accuracy through modeling of process-specific deviations. Potential multidimensional regression methods for modeling such deviations are compared. Supported by artificial neural networks, extensive handling operations are performed by a robot-based fuel cell stacking system. The results are statistically evaluated and discussed with regard to precision. [ABSTRACT FROM AUTHOR]

A major driver for competition in end-consumer markets is product individualization with regard to functionalities, shape and design. This trend calls for more flexible and versatile production systems. In anticipation of this challenge a new concept for form-flexible handling devices is proposed. It involves a vacuum system in combination with a gripper cushion that is filled with granules. The novel working principle demands a model based design to realize a fast process integration. The feasibility of this concept and the design process are shown in a preforming process. Benefits of such handling tools in versatile production systems are discussed. [ABSTRACT FROM AUTHOR]

It is currently not possible to omit cutting fluid in honing processes due to the relatively low cutting speeds and the planar contact between workpiece and honing stone and the therefore needed flushing capability for chip removal. Resource efficiency can be maximized during the honing process by replacing mineral oil based honing oil with an alternative fluid. In this study grey cast iron was honed under the application of honing oil and mineral oil free cutting fluid, henceforth referred to as polymer dilution. The obtained results showed that the polymer dilution leads to higher achievable specific material removal rates with concurrently lower surface roughness compared to the application of mineral based honing oil. [ABSTRACT FROM AUTHOR]