Automated Production of Lightweight Parts

Abstract

This Master Thesis is made within Deutsche Zentrum für Luft und Raumfahrt e.V (DLR). The Automotive Concept Institute of DLR develops lightweight prototype called Safe Light Regional Vehicle (SLRV), the body construction of SLRV uses sandwich panels as the main structure. All of the carrosserie in SLRV was handcrafted, this makes the production inefficient and costly. This project aims to solve that problem by developing an automation concept for manufacturing front structure of SLRV. With the help of automation, cost reduction and increased in efficiency for potential mass production is expected. The proposed concept is focused on using a low-cost robot which is using Raspberry Pi for the robot control. The final goal for this project is the production of bottom part of the front structure from SLRV which has three stations: 1. Inserting Inserts Station 2. Applying Adhesive Station 3. Assembling Metal Sheets Station To help the production of lightweight structure (sandwich structure), computer vision, industrial robot, pick and place robot method, and Industry 4.0 principles are applied throughout the process of developing Automated Production of Lightweight Parts.