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Welding end-effectors ready for demonstrator assembly

Endraß, Manuel and Engelschall, Manuel and Jarka, Stefan and Mayer, Monika and Schuster, Alfons and Vistein, Michael and Bauer, Simon and Gänswürger, Philipp and Fischer, Frederic (2021) Welding end-effectors ready for demonstrator assembly. DLR-Interner Bericht. DLR-IB-BT-AU-2021-210.

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This report deals with the overall description of the functionality of the developed and matured welding end-effectors as well as with the concept for automated control and the accompanying inline quality assurance for the upper test shell manufacturing. Ultrasonic spot welding, continuous ultrasonic welding and resistance welding can be named as applied welding technologies within the MFFD`s upper shell assembly. Customized welding end-effectors for the integration of stringers and cleats were designed and manufactured. Here special focus was set on the end-effectors for continuous ultrasonic welding (CUW) and cleat integration. The CUW end-effector underlies continuous improvements that are described later on. For cleat integration a series of two robots, a KUKA LBR with the attached cleat end-effector mounted on a KUKA KR270 was chosen as solution for the force- and torqueless cleat integration. Special focus was set on high flexibility of the assembly jigs and processes in order to overcome with the challenges of single part tolerances and its compensation during assembly. Skin manufacturing and the structure assembly is monitored by an integrated inline quality assurance system.

Item URL in elib:https://elib.dlr.de/146918/
Document Type:Monograph (DLR-Interner Bericht)
Title:Welding end-effectors ready for demonstrator assembly
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Endraß, ManuelUNSPECIFIEDhttps://orcid.org/0000-0003-4133-0834UNSPECIFIED
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501UNSPECIFIED
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Vistein, MichaelUNSPECIFIEDhttps://orcid.org/0000-0001-6998-0017133661193
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Date:30 April 2021
Refereed publication:No
Open Access:No
Keywords:Multifunctional Fuselage Demonstrator, Thermoplastic Composites, LM-PAEK, Welding Technologies, Dustless Joining, Continuous Ultrasonic Welding, Resistance Welding
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Components and Systems
DLR - Research area:Aeronautics
DLR - Program:L CS - Components and Systems
DLR - Research theme (Project):L - Production Technologies
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Fischer, Frederic
Deposited On:09 Dec 2021 10:50
Last Modified:24 Apr 2023 13:31

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