Autonomous preforming system: automated and sensor-aided handling of dry carbon fibre textiles

Abstract

Preforming of carbon fibre reinforced plastic (CFRP) parts is one of the most difficult and time consuming manufacturing processes for large aircraft structures. The main challenges are the handling and draping of flexible fabrics into complex curved geometries to achieve the defined fibre angles which are mandatory for the required mechanical properties of the part. At the Centre for Lightweight Production Technology (ZLP) of the German Aerospace Centre (DLR) in Augsburg automation solutions for such manufacturing processes of full scale aircraft structures are developed. This paper presents an approach for a dynamic patch preforming method for dry carbon fibre textiles. The goal was the automation of the process with focus on digitalization. To identify essential automation steps the process chain was analyzed and described. The automation for the dynamic preforming was established with an industrial robot cell and a mechanical end effector. The end effector is capable of deforming to fit complex curvatures and handling of cut pieces regarding the draping simulations. A digitalized model of the end effector was used to simulate its deformation. Furthermore the detection, autonomous handling and movement monitoring of cut pieces is explained. Finally an automated process for a full scale Rear Pressure Bulkhead (RPB) patch preforming was set up and realized.