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Norwegian University of Science and Technology
Robotic welding of aluminiumProfessor Olav Egeland
Seminar
Ålesund 2019-02-13
Norwegian University of Science and Technology 2
Robotics and Automation Group
Department of Mechanical and Industrial Engineering, NTNUProfessor Olav Egeland, Head of Group
Professors
• Olav Egeland: Production Automation
• Amund Skavhaug: Embedded Computer Systems
• Christian Holden: Subsea Control Systems
• Lars Tingelstad: Robotic Production
Lecturer
Kristine Thevik: Robotics and Mechatronics
Professor II
• Stig Pedersen, IIoT and Industry 4.0
• Gunleiv Skofteland, Offshore Control Systems
Research Engineer
• Dr. Adam Leon Kleppe
Norwegian University of Science and Technology
Quantec Robot Cell
Robot Cell for Heavy Welding and Assembly
• 2 Large 120 kg Robots
• 2 Welding Robots
• Fronius TransSteel MIG/MAG welding system
• Vision, Force Control
• Off-line Programming
• KUKA Industrial control system with ROS extension
Norwegian University of Science and Technology 4
Utfordringer med innføring av robotisert produksjon
Problemer med dagens teknologi:
• Proprietære protokoller
• Betydelig engineering av avanserte celler
• Tidkrevende kalibrering og igangkjøring
3D kamera
Robot-kontroller
PC
Seise-utstyr
GS
PLS
GS
GriperSikkerhets-utstyr
Frese-verktøy
Robot-kontroller
GS
Ethernet
EtherCAT
EtherCAT
EtherCAT
PROFINET
PROFINET
PROFINET
EtherCAT
Modbus
Robotcelle ved MTP
Norwegian University of Science and Technology 5
Industri 4.0:
Robot cell
Production Line World
Internet of Things Security
VisionSystemsAssembly
instructions
Operator
CAD-models
MonitorCloud Mobile app Internet
Main elements
• Cyber-physical systems with local intelligence
• Internet of Things
• Sensorer
• Digitale models
Main principles
• Open protocols for communication
• Local intelligence
• Automatic configuration
• Functional integration
Norwegian University of Science and Technology
Industri 4.0 for Norwegian Industry
Characteristics of Norwegian production:
• Small series, ETO
• Advanced products of high added value
• Specialized competence towards
– Maritime sector
– Oils and gas industry
– Renewable energy
– Fish farming
• Commercially available robotics is specialized for the automotive industry
• Norwegian industry requires
– Rapid changeover between different product variants
– Advanced robotic systems that are profitable for small series
Norwegian University of Science and Technology
Digital twin: A digital copy of a production line
• For simulation of production
• 3D graphics
Applications
• Planning and design of new production facilities
• Planning and design of layout of robot cells
• Planning og logistics and production of variants
• Supervision and control in real time
• Report generation:
– Product flow through production line
– Bottleneck reporting
– Product in internal storage
– Efficiency of machine centers
Machine Center 1
Storage Paint Line
Digital twins
Machine Center 2
Storage
Norwegian University of Science and Technology
Robot Technology Levels
Teach-Pendant
Programming
Offline Programming
Digital factories,
cyber-physical
systems and IoT
Simple tasks, small
batches
Advanced products, larger
batches
Technological
sophistication
Off-the shelf industrial technology Advanced industrial
technology
Next generation production
systems
Level of
Competence
Integration of CAD,
robotic production and
vision systems
Automatic one-piece
productionIndustry 4.0
Norwegian University of Science and Technology 9
KPN: Robotic welding of aluminium hulls
• Goal:
– New technology and methods for efficient robotic welding of large aluminium structures.
– Cost effective production of aluminium hulls in Norway
• Integration of CAD, ship design, robot programming and welding
• Improved control and documentation of welding process with possible design implications.
• Project Manager: Professor Olav Egeland, NTNU
• 4 PhD scholarships.
• Industry partners: Hydro, Fjellstrand, Leirvik, Digitread
• The project will use the new robotic welding lab of ManuLab
– Welding lab: 6.5 mill. NOK
– Industry 4.0 lab: 6 mill NOK
Project start: Q2 2019
Norwegian University of Science and Technology
Traditional geometry
with shear connectionFloating frameGeometry without
shear connection
±X
mm
Shear connection
using extra part
Alternative designs for welding of aluminium hulls
Norwegian University of Science and Technology 11
Welding of aluminium: Some challenges
• Aluminium deforms to a larger extent than steel under welding.
• Less material may be added than for steel
• Sensors are important to compensate for deformation
• The surface oxide has a high melting temperature and may cause reduce weld quality.
• Aluminium welds absorbs hydrogen
• Tracking of weld with pendulum motion is more difficult than for steel.
• The surface oxide makes touch sensing more difficult than for steel
• The aluminium surface is highly reflective, which is a challenge when robot vision and laser systems are used
Norwegian University of Science and Technology
Integrated Design, Production and Documentation
• Integration of CAD systems and 3D simulation tools are available for production lines and robots
– Siemens NX, Teamcenter and Tecnomatix Robot Expert
– Dassault: CATIA and Delmia
– Visual Components, KUKA.Sim, ABB Robot Studio
• Automatic production of product families based on CAD is possible
• Robot vision is used for calibration of geometry
• Welding parameters can be included in the CAD
• Metrology and documentation can be integrated
Norwegian University of Science and Technology 13
Industri
4.0 lab
• 5 Robots
• One collaborative robot with 7 joints
• Two 7DOF robots
• Two KUKA KR6 Agilus
New Robot Welding Lab at NTNU
Norwegian University of Science and Technology 14
AGV-lab
• 2 robots
• Each AGV has a 7DOF robot arm.
Norwegian University of Science and Technology 15
Robotic
Welding
• 8 robots
• MIG, TIG og CMT welding
• Grinding and polishing capability
ROBOTIC WELDING LAB
ROBOTIC WELDING LAB
Large welding cell
• 1 stationary robot
• 1 robot on track
• Positioning table with 2 axes and 5 tonnes capacity.
Grinding and finishingcell
• 2 large KUKA KR120 robots with 2.5 m reach and 120 kg lifting capacity
• Closed area