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1Universität RostockLehrstuhl Fertigungstechnik

Presentation of the Research Areas of the Fraunhofer Application Center in Rostock

Universität RostockLehrstuhl Fertigungstechnik

Presentation of the Research Areas of

the Fraunhofer Applikation Center in

Rostock

Dipl.-Ing. Ralf Glienke

METNET ANNUAL SEMINAR ROSTOCK 7TH AND 8TH OCTOBER 2008



INTRODUCING THE FACILITY



1. 1 Introducing of the Facility Locations of Fraunhofer Gesellschaft FhG

80 research units

at approx. 40 locations

Fraunhofer Application Centre Rostock,Joachim-Jungius-Str. 9 (in RIGZ)

Technikum

RIGZ

The Fraunhofer Gesellschaft in Germany

56 Institutes

13 000 Employees

1.3 billion € Budget

17

2

Global Locations of Fraunhofer

Institutes

Branches of Institutes, Research Institutions, Working Groups, Branch Labs, Application Centers



1.2 Introducing the FacilitiesCooperation Professorship of Manufacturing Engineering (IfF) and Fh-Application Centre (AGP)

Professorship:

Prof. Dr.-Ing. Martin-Christoph Wanner

Address: Albert-Einstein-Straße 2

18051 Rostock

+49(0)381/4059-713

+49(0)381/4059-694

URL: http://www.hro.ipa.fraunhofer.de/fhg/agp_iff/ E-Mail: [email protected]

Director:

Prof. Dr.-Ing. Martin-Christoph Wanner

Address: Joachim-Jungius-Straße 9 (RIGZ)

18059 Rostock

+49(0)381/4059-720

+49(0)381/4059-694

Albert-Einstein-Str.30

18059 Rostock (Laboratory)

URL: http://www.hro.ipa.fraunhofer.de E-Mail: [email protected]

Situation July 2008:

Number of employees: 33 scientific and technical staff (full-time)

58 students (part-time)

Future perspective: enlarge the number of scientific employees

Universität RostockFakultät für Maschinenbau und Schiffstechnik

Lehrstuhl Fertigungstechnik



1.3 Introducing the FacilityEquipment (June 2008)

Buildings, Offices, Infrastructure

Test Areas & Laboratories

Special Equipment

• ca. 350 m2 Fh AGP-RIGZ (Joachim-Jungius-Str. 9)

• ca. 160 m2 Fh AGP-Laboratory (Albert-Einstein-Str. 30)

• ca. 34 m2 Professorship Manufacturing Engineering (Warnemünde)

• ca. 520 m2 Fh AGP-Laboratory (Albert-Einstein-Straße 30)

• ca. 420 m2 Laboratory of welding technology (Warnemünde)

Laboratory of:

„ Production engineering and machine tools

„ Welding technology

„ Mechanical joining

Laboratory Fraunhofer Application Centre

Albert-Einstein-Straße 30

„ Robotics and automation technology

„ Production measurement technology

„ Ship production technology

„ Planning and organization of factories

„ Virtual development of installations and machines



1.4 Introducing the FacilityOrganisation of the Institute

Institute Management

Univ. Prof. Dr.-Ing. Martin-Christoph Wanner

Dr.-Ing. Knuth-Michael Henkel (Deputy)

Production Engineering Organization Laboratories

Dr.-Ing. K.-M. HenkelUniv. Prof.

Dr.-Ing. M.-C. WannerDipl.-Ing. W. Fritsche

Automation Systems,

Quality Engineering

Univ. Prof.

Dr.-Ing. M.-C. Wanner

Development Team

Welding Technology

Project Team MAPRO

University of Rostock

Dipl.-Wirt. Ing.

B. Weidemann

Development Team

Prototypes

Dipl.-Ing. (FH)

U. PfletscherDipl.-Ing. M. Anders

Development Team

Measuring of

large structures

Dipl.-Ing. O. Grewe

Development Team

Mechanical Joining

Dipl.-Wirt. Ing. N. Fuchs



1.5 Introducing the FacilityResearch Areas

Research Area Focus Ships, Offshore

Civil engineering, steel

building, aicraft building,

rail stock Building

Regionale

Research

Production

Processes

Automation

Systems

Quality

engineering

Company and

production

organization

Product

development

Mechanical joining, welding, cutting and

metal forming

Measuring, sensor, robotics and control

engineering

Measuring of largegeometric structures,

image processing, weld-

ability and fatigue strength

Company concepts, cooperation networks,

production organization

and logistics

Maritime industry, steel construction etc.

0

50

100

150

200

250

300

350

0.0 0.5 1.0 1.5 2.0 2.5 3.0

Dehnung in %

Sp

an

nu

ng

in

N/m

m^2

0 10 20 30

0,0

0,5

1,0

1,5

Traversenweg in mm

Kra

ft in

kN



1.6 Fields of StudyBachelor and Master Courses for Industrial and Mechanical Engineering

Manufacturing Welding AutomationQualityShipbuilding

Professorship of Manufacturing Engineering

Manufacturing

Technology

Selected

Manufacturing

Processes

Machine Tools

Welding

Technology

Welding

Construction

Welding

Metallurgy

Ship Production

Engineering I

Ship Production

Engineering II

Quality

Management

Production

Measurement

Technology

Technical

Documentation

Automation

in Manufacturing

and Assembly

Control

Engineering

Robotics



1.7 Turnover of IfF and FhG– Annual Balances –

T €

Year

0

200

400

600

800

1000

1200

1400

1600

1800

2000

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

366 434 367504 548

723844

1029 990

1278

239275 410

343

496

447

418

402

284

679

IfF (Professorship Manufacturing

Engineering)

Fh AGP



CHOSEN AREAS OF RESEARCH



2.1 Production of Coating Suitable Edges in Shipbuilding

Benefit

„ Introduction of modified plasma cutting and welding systems

for automatic and reproducible edge bends in shipyards

„ Decrease of processing time through reduction of manual

“sanding work“ at “free edges”

Solution

„ Systematic plasma bend testing with diverse alternatives of modulation in

terms of gas combinations, jets, amount of gas and alternatives of flow

„ Operational parameter testing in existing and innovative burner

configurations

„ Functional capability testing of the developed plasma cut modules within

selected cutting systems

Problem

„ The International Maritime Organization (IMO) demands a 15

year durability of coatings

„ Intensification of standards through the passage of

„Performance Standard for Protective Coatings“

„ Demanded coating suitable edge radius of R ≥ 2mm for “free

edges“

„ Manual “cleaning and sanding work“ for each containership

takes up to 3.000 h

„ Shortcoming of information about possibilities in efficient

parallel and thermic downstream edge working in connection

to corrision resistance

R=2,6 mm

Test set-up: plasma cutting and plasma welding burner in the process of cutting and radiusing (picture 1 and 2)

shipbuilding subspecimen (picture 3); operating plasma welding arc (picture 4) for parallel downstream edge

radiusing of structures in shipbuilding technology (picture 3) radiused edges with grinding pattern after plasma

welding procedure (pictures 5)

1 2

3

4

5



2.2 Flange Load Bearing Capacityof Blind Rivet (BR) and Retaining Ring Bolt (RRB)

Problem

„ Verification of fluid and pressure tightness demanded in vehicle, steel and

facade engineering

„ Only empiric solutions have been detected so far

„ Therefore the connections are often oversized and sealing material is added

Solution

„ Classification of applications and of suitable sealants

„ Testing of static and dynamic load

capacity and of the clamping force of selected flange geometries

„ Experimental testing of aging, medium capacity, and creep tests

„ Development of methods and evidences

for the technical dimensioningBenefit

• Assembly features and quality with practical relevance derive from the findings and the area of application can be extended considerably

Construction of railway vehicles:

Ensure tightness of roof, floor, and side module connections (picture:

Fa. Bombardier GmbH)

steel / vehicle engineering:

Assure tightness of mechanically joined

modules/ hinges / fixtures

Verbindungselemente

Dichtstoff

Schematical flange dynamometer

for tightness examinations with

diverse test media (fluids, gases)

Numeric examination of deformations subject to different

composing orders



2.3 Optimizing the Production of Panel Formwork Elements

Problem

Solution Benefit

„ Increasing the cost efficiency of the manufacturing process of

panel formwork elements

„Examination of alternatives in dimensioning and

manufacturing, and detection of potential for optimization

within the process of manufacturing

„Comparison of alternatives and cost analysis of single and

combined operational optimizations regarding realization

and automation

„ In concrete formwork,

panel formwork elements

have to be highly stressable

and tough but they also

have to be economically

manufacturable

„Present production flows

are examined and

potentials for optimization

are detected to increase the

operational throughput

Panel formwork elements with different heights

and widths for the economic development of

large-area walls, bearings, circular formwork,

and foundations

Examples for the application of panel formwork with angles,

bulkhead formwork, and T- fitting for the adjustment to every

form of ground plan (right) and the construction of the highest

building in the world at a height of 600 m (left)



2.4 Development concept of an innovative large gate

Benefit

„ The gate to be developed requires low investment

expenditures, running costs are considerably lower compared

with conventional industrial gates, fast opening and closing

times are possible

„ Taking into account existing and future European

standards for safe and environmentally friendly operation

development of a new gate mechanism having a flat door

outside and few thermal cold bridges

„ Designing an economic production and assembly schedule

for the production of large gates

„ At present section gates and sliding gates for hangars

are composed of very many individual elements which

cause a high expenditures for material and assembly, a

lot of refinishing work, high wear, frequent

maintenance work and insulation weakness. All these

problems are leading to growing customer

dissatisfaction.

Solution

Problem

Development of an innovative gate of a passage height of

30 m x 9 m in modern design:



2.5 Evenness Measurements of Selected Flange Connections

Solution

Benefit

„ Effective possibility if evenness measurement of highly-accurate flange

connections under difficult measuring conditions

„ Very well suited for repeated measurements

„ Measurement results form the basis of an aimed re-designing of the

construction as well as of the welding methodology

„ Evenness measurement by means of digital photogrammetry

„ Comparing the measurement data with a medium level

„ Comparing starting states with final states

„ Graphic and numeric display of measurement results

„ High evenness requirements (σ = ± 0.15 mm) on flange connections

e. g. crane pilar - crane sluing rig or fundament of a POD drive

„ Loss of evenness at the surface of a flange by subsequently carried

out welding connections

„ Feasibililty of the evenness measurement independent of place and

position of the flange (e. g. contruction position; on board)

Flange levels

Evenness analysis

Measurement picture

Problem



2.6 Brodotrogir Shipyard (Croatia) –Simulating Modells for Future Spaces and their Use

Solution

Benefit

„ Fast realization of investments and minimum failure during the phase of realization

„ Simple decision-making in case of the investor‘s change request

„ Demonstration of the gradational restructuring of

resources in the manufacturing concept for the present

owner and future investors

„ Early realization of the shipyard‘s restructuring on the

basis of existing information and plan of procedures

after a decision of the present owner

„ Development of a detailed layout model of all

resources as well as of a gradational model for

investments in the shipyard

„ Improvement of the current situation of production

organization in preparation for changes within the

manufacturing concept

„ Preparation of the offer phase with a specification

description of all systems and equipments in the

shipyard

Problem



2.7 Pilot Plant for Image Recognition Based Programming of Rail Welding Robots

Problem

Solution

Benefit

„ The development work for the programming of welding robots has

been successfully finished but the applied realization of a

manufacturing plant is still missing

„ For reasons of capacity the image recording has to be decoupled

from the welding robot.

„ The existing micro panel line of the Warnow

Werft in Warnemünde will be enlarged through a

new image recording device provided by the Fh-

AGP.

„ The image recording will be spacially and

temporally seperated from the robots and will be

installed at a so far unused buffer place of the

line.

„ Fully automated programming through image recording

„ Improvement of division of responsibilities among the

robots

„ Increase in productivity at minimum non-productive timesImage recording portal with longitudinal and swivel axis

Roboterarbeitsplatz

1

Roboterarbeitsplatz

2

Querverschiebung

Eingang

Bilderfassung

Auflege- und

Heftstation

Roboterarbeitsplatz

3

Abnahmestation

Querverschiebung

Ausgang

Auflege- und

Heftstation

Richten

(Gegenschrumpfen)

Roboterarbeitsplatz

1

Roboterarbeitsplatz

2

Querverschiebung

Eingang

Bilderfassung

Auflege- und

Heftstation

Roboterarbeitsplatz

3

Abnahmestation

Querverschiebung

Ausgang

Auflege- und

Heftstation

Richten

(Gegenschrumpfen)

Integration of image recording into an existing panel line

Crosswise translational displacement Entry

image acquisation

Application

and stapling

station

Acceptance

Application

and stapling

station

Crosswise translational displacement Exit

robot workstationrobot workstationrobot workstation



2.8 Extension of the Insitute ComplexFuture Facilities until 2010



THANK YOU FOR YOUR ATTENTION.

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