Fachbereich Maschinenbau und Mechatronik
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Der Embedded Wireless-Report
(2014)
Feldbustechnologie
(2014)
Generation Y
(2014)
Today, the assembly of laser systems requires a large share of manual operations due to its complexity regarding the optimal alignment of optics. Although the feasibility of automated alignment of laser optics has been shown in research labs, the development effort for the automation of assembly does not meet economic requirements – especially for low-volume laser production. This paper presents a model-based and sensor-integrated assembly execution approach for flexible assembly cells consisting of a macro-positioner covering a large workspace and a compact micromanipulator with camera attached to the positioner. In order to make full use of available models from computer-aided design (CAD) and optical simulation, sensor systems at different levels of accuracy are used for matching perceived information with model data. This approach is named "chain of refined perception", and it allows for automated planning of complex assembly tasks along all major phases of assembly such as collision-free path planning, part feeding, and active and passive alignment. The focus of the paper is put on the in-process image-based metrology and information extraction used for identifying and calibrating local coordinate systems as well as the exploitation of that information for a part feeding process for micro-optics. Results will be presented regarding the processes of automated calibration of the robot camera as well as the local coordinate systems of part feeding area and robot base.
An increasing amount of popular articles focus on making models and sculptures by 3D Printing thus making more and more even private users aware of this technology. Unfortunately they mostly draw an incomplete picture of how our daily life will be influenced by this new technology. Often this is caused by a very technical point of view based on not very representative examples. This article focuses on the peoples needs as they have been structured by the so-called Maslow pyramid. Doing so, it underlines that 3D Printing (called Additive Manufacturing or Rapid Prototyping as well) already touches all aspects of life and is about to revolutionize most of them.
Additive Manufacturing durch Aufschmelzen von Metallpulvern hat sich auf breiter Front als Herstellverfahren, auch für Endprodukte, etabliert. Besonders für die Variante des Selective Laser Melting (SLM) sind Anwendungen in der Zahntechnik bereits weit verbreitet und der Einsatz in sensitiven Branchen wie der Luftfahrt ist in greifbare Nähe gerückt. Deshalb werden auch vermehrt Anstrengungen unternommen, um bisher nicht verarbeitete Materialien zu qualifizieren. Dies sind vorzugsweise Nicht-Eisen- und Edelmetalle, die sowohl eine sehr hohe Reflektivität als auch eine sehr gute Wärmeleitfähigkeit aufweisen – beides Eigenschaften, die die Beherrschung des Laser-Schmelzprozesses erschweren und nur kleine Prozessfenster zulassen. Die Arbeitsgruppe SLM des Lehr- und Forschungsgebietes Hochleistungsverfahren der Fertigungstechnik hat sich unter der Randbedingung einer kleinen und mit geringer Laserleistung ausgestatteten SLM Maschine der Aufgabe gewidmet und am Beispiel von Silber die Parameterfelder für Einzelspuren und wenig komplexe Geometrien systematisch untersucht. Die Arbeiten wurden von FEM Simulationen begleitet und durch metallographische Untersuchungen verifiziert. Die Ergebnisse bilden die Grundlage zur schnellen Parameterfindung bei komplexen Geometrien und bei Veränderungen der Zusammensetzung, wie sie bei zukünftigen Legierungen zu erwarten sind. Die Ergebnisse werden exemplarisch auf unterschiedliche Geometrien angewandt und entsprechende Bauteile gezeigt.
Although Selective Laser Melting (SLM) process is an innovative manufacturing method, there are challenges such as inferior mechanical properties of fabricated objects. Regarding this, buckling deformation which is caused by thermal stress is one of the undesired mechanical properties which must be alleviated. As buckling deformation is more observable in hard to process materials, silver is selected to be studied theoretically and experimentally for this paper. Different scanning strategies are utilized and a Finite Element Method (FEM) is applied to calculate the temperature gradient in order to determine its effect on the buckling deformation of the objects from experiments.
In this research work, a statistical analysis of the CO2 laser beam welding of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets was done using response surface methodology. The analysis considered the effect of laser power (2–2.2 kW), welding speed (40–50 mm/s) and focus position (−1 to 0 mm) on the heat input, the weld bead geometry, uniaxial tensile strength, formability limited dome height and welding operation cost. The experimental design was based on Box–Behnken design using linear and quadratic polynomial equations for predicting the mathematical models. The results indicate that the proposed models predict the responses adequately within the limits of welding parameters being used and the welding speed is the most significant parameter during the welding process.
Generally, the quality of a weld joint is directly influenced by the welding input parameter settings. Selection of proper process parameters is important to obtain the desired weld bead profile and quality. In this research work, numerical and graphical optimization techniques of the CO2 laser beam welding of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets were carried out using response surface methodology (RSM) based on Box–Behnken design. The procedure was established to improve the weld quality, increase the productivity and minimize the total operation cost by considering the welding parameters range of laser power (2–2.2 kW), welding speed (40–50 mm/s) and focus position (−1 to 0 mm). It was found that, RSM can be considered as a powerful tool in experimental welding optimization, even when the experimenter does not have a model for the process. Strong, efficient and low cost weld joints could be achieved using the optimum welding conditions.
The laser beam-submerged arc hybrid welding method originates from the knowledge that, with increasing penetration depth, the laser beam process has a tendency to pore formation in the lower weld regions. The coupling with the energy-efficient submerged-arc process improves degassing and reduces the tendency to pore formation. The high deposition rate of the SA process in combination with the laser beam process offers, providing the appropriate choice of weld preparation, the possibility of welding plates with a thickness larger than 20° mm in a single pass, and also of welding thicker plates with the double-sided single pass technique.
Electron beam plasma measurement was realised by means of DIABEAM system invented by ISF RWTH Aachen. The Langmuir probe method is used for measurement. The relative simplicity of the method and the possibility of dispersion of high power on the probe allow its application for the investigation of high-power electron beams. The key element of the method is a rotating thin tungsten wire, which intersects the beam transversely on its axis and collects part of the current by itself. The signals, which are registered in the DIABEAM as a voltage, were taken in the form of amplitude. The conversion of the probe current into the distribution along the beam radius was realised using the Abel’s method. A voltage-current characteristic was built for the beam current. The local electron density as well as the electron temperature, the floating potential and the plasma potential were measured and calculated by means of this characteristic.
Im Rahmen des Exzellenzclusters „Integrative Produktionstechnik für Hochlohnländer“ der RWTHAachen University werden derzeit alternative Verfahren zur Herstellung von Metall/Kunststoff- Verbindungen untersucht. Eines davon ist das thermische Direktfügen, das eine stoffschlüssige Verbindung zwischen Kunststoff und Metall ermöglicht und ohne die Verwendung von Klebstoffen, Haftvermittlern oder mechanischen Verbindungshilfen auskommt.