Research group Processes and automation

In order to meet the challenges in the aerospace industry, new automation approaches are required that are specifically tailored to the comparatively low production rates and the high number of variants. These approaches should lower the investment hurdles and at the same time increase process robustness and component quality.

Process design

Our Process and Automation (PNA) team focuses on the development of flexible, sensor-based and robust production processes and handling technologies.

In order to develop cost-efficient components, it is crucial to consider potential manufacturing processes and their boundary conditions as early as the component design stage. This integrative approach enables the development of holistically optimised process and component designs.

Process expertise

In our PNA team, we deal with manufacturing processes along the entire process chain, from material delivery to the finished component.

Thanks to our many years of experience and in-depth knowledge of modern manufacturing technologies, we are able to

  • identify the essential, cost-relevant processes,
  • understand interfaces and their challenges,
  • recognise potential for optimisation and automation.

Building on this, we develop innovative and efficiently automated processes for the robust production of tomorrow.

Demonstration on an industrial scale

Our aim is to validate the developed production technologies and process chains on a full-scale under industrial conditions.

In close cooperation with our partners, we therefore develop automation solutions in our industrial plants. In this way, we optimise manufacturing processes in terms of speed, efficiency, reproducibility and sustainability. Together, we develop targeted solutions for our partners' challenges.

FML (2 end effectors)
GLEN (for glare end effectors) is a tool designed for the 'pick & place' lay-up of fibre metal Laminates (FML) made from aluminium and glass fibre prepregs. The geometry is adjustable to cylindrical shapes on-the-fly. Gripper configurations for both materials are available that can be changed between tasks. The interplay of two end effectors in a robotic team enables the production of large-area FML components.
Image: 1/8, Credit:

DLR (CC BY-NC-ND 3.0)

Vacuum bagging
Robotic application of auxiliary materials for vacuum bagging on large 3D and 2D geometries. Application of auxiliary material packages on a full-scale spherical geometry of an rocket booster case (Ariane 6).
Image: 2/8, Credit:

DLR (CC BY-NC-ND 3.0)

P&P large cut (2 end effectors)
Cooperative depositing of large carbon fibre blanks with 'pick & place' process The end effectors can be passively adjusted to spherical geometries by the robot using an external tool. Draping takes place during the rolling pick-up movement.
Image: 8/8, Credit:

DLR (CC BY-NC-ND 3.0)

Contact

Matthias Beyrle

German Aerospace Enter (DLR)
Center for Lightweight-Production-Technology (ZLP)
Institute of Structures and Design
Am Technologiezentrum 4, 86159 Augsburg