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Robot-based Continuous Ultrasonic Welding for Automated Production of Aerospace Structures

Engelschall, Manuel and Larsen, Lars-Christian and Fischer, Frederic and Kupke, Michael (2019) Robot-based Continuous Ultrasonic Welding for Automated Production of Aerospace Structures. SAMPE Europe Conference 2019, 17. - 19. September 2019, Nantes, Frankreich. ISBN 978-90-829101-1-7

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Abstract

Thermoplastic composite materials for structural aircraft components offer advantages in terms of performance and efficient production. In this context, ultrasonic welding is a promising joining technique that could replace the classical mechanical fastening by riveting and bolting which requires extensive drilling and sealing. At the Center for Lightweight Production Technology (ZLP) in Augsburg a robot-based continuous ultrasonic welding system has been developed. It consists of an end-effector mounted on a standard industrial robot, which allows the flexible joining of large flat and double-curved structures. The functional efficiency has already been proven on various components such as a stiffened fuselage panel or a rear pressure bulkhead. In order to benefit from the high welding speed this fusion bonding process is currently being matured to further improve robustness. A parameter study was carried out to identify optimized processing parameters.

Item URL in elib:https://elib.dlr.de/130797/
Document Type:Conference or Workshop Item (Speech)
Title:Robot-based Continuous Ultrasonic Welding for Automated Production of Aerospace Structures
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Engelschall, ManuelManuel.Engelschall (at) dlr.deUNSPECIFIED
Larsen, Lars-Christianlars-christian.larsen (at) dlr.dehttps://orcid.org/0000-0002-4450-8581
Fischer, FredericFrederic.Fischer (at) dlr.dehttps://orcid.org/0000-0001-5421-4336
Kupke, Michaelmichael.kupke (at) dlr.deUNSPECIFIED
Date:September 2019
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
ISBN:978-90-829101-1-7
Status:Published
Keywords:Automated Production, Robot-based Continuous Ultrasonic Welding Thermoplastic Composites, Mechanical Testing, Coupon Testing, Carbonfiber Reinforced Thermoplastic, CF/PPS
Event Title:SAMPE Europe Conference 2019
Event Location:Nantes, Frankreich
Event Type:international Conference
Event Dates:17. - 19. September 2019
Organizer:Sampe Europe
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design
Institute of Structures and Design > Automation and Production Technology
Deposited By: Engelschall, Manuel
Deposited On:28 Nov 2019 10:25
Last Modified:28 Nov 2019 10:25

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