Automation and Production Technology

Fraunhofer IFAM in Stade

The mobile CNC machining robot on a mobile platform (AGV; ProsihP II project) developed at the Fraunhofer IFAM in Stade machines the vertical stabilizer of an A 320 on a 1:1 scale with high precision.
© Fraunhofer IFAM
The mobile CNC machining robot on a mobile platform (AGV; ProsihP II project) developed at the Fraunhofer IFAM in Stade machines the vertical stabilizer of an A 320 on a 1:1 scale with high precision.
Newly developed machining robot from Stade closes the gap between conventional industrial robots and machine tools: The flexible milling kinematics on a linear axis (RoMaNi project) enables high-precision machining of fiber composites, aluminum and hardened and tempered steels with a manufacturing tolerance of up to 0.1 millimeters.
© Fraunhofer IFAM
Newly developed machining robot from Stade closes the gap between conventional industrial robots and machine tools: The flexible milling kinematics on a linear axis (RoMaNi project) enables high-precision machining of fiber composites, aluminum and hardened and tempered steels with a manufacturing tolerance of up to 0.1 millimeters.
The “MultiFAL” assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.
© Fraunhofer IFAM
The “MultiFAL” assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.

The Fraunhofer IFAM branch at the Research Center CFK NORD in Stade, Germany, has been offering research and development services for the sustainable machining and assembly of large lightweight structures made of various materials since 2010. Orders from the wind turbine, commercial vehicle and rail vehicle construction as well as the agricultural sector are increasingly expanding the focus of R&D activities for aircraft construction.

Process and system development up to 1:1 scale for the Smart Factory

When transferring R&D results from the laboratory or pilot plant, the “upscaling” to real production conditions is often a particularly time-consuming and cost-intensive phase. In order to reduce the resources of customers, Fraunhofer IFAM enables them to validate the step from the laboratory to a production-analog environment with real components on a 1:1 scale in its own premises and equipments. Among other things, a 4000 m2 research hall with a height of 15 m under crane hooks is available for this purpose, including many flexibly configurable large-scale research systems equipped with robots, holding fixtures and high-performance measurement technology.

Fraunhofer IFAM supports companies efficiently in a wide range of areas: from feasibility studies for processes on small to large components, through production process design and optimization, up to the development and practical testing of new technology modules. Support in the implementation of the new technology modules and processes in customer-specific production rounds off the service portfolio.

Modular automation and digitalization solutions for large lightweight structures

The range of products and services is divided into existing automation and digitalization technology modules, which can be combined into complete solutions in line with customer requirements, as well as fundamental new developments tailored to customer specifications for large-scale automation. This covers the core areas of:

Efficient, sustainable and ergonomic large-scale structure assembly

The challenge currently facing large-scale assembly is to combine efficiency, sustainability and ergonomic workplace design. The key principles guiding the search for solutions are “automation not at any price” and “smart solutions using sensor technology or artificial neural networks”. And: people must feel welcome and comfortable in this new working environment.

Transfer of currently manually performed drilling processes at CFRP vertical tail planes to mobile cobots. The modular system developed for lightweight robot applications (CoMMaNds 2 project) enables lightweight robot systems to be configured and reconfigured with reduced time and financial outlay.
© Fraunhofer IFAM
Transfer of currently manually performed drilling processes at CFRP vertical tail planes to mobile cobots. The modular system developed for lightweight robot applications (CoMMaNds 2 project) enables lightweight robot systems to be configured and reconfigured with reduced time and financial outlay.
Modular robotic system which can move anywhere an AGV can go, that can be reassembled for different purposes and set up to be working independently without blocking an AGV (Project RoboCoop).
© Fraunhofer IFAM
Modular robotic system which can move anywhere an AGV can go, that can be reassembled for different purposes and set up to be working independently without blocking an AGV (Project RoboCoop).
The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is operated by virtually coupled AGV systems, transports the precisely positioned CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.
© Fraunhofer IFAM
The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is operated by virtually coupled AGV systems, transports the precisely positioned CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.
The “sensor box” developed by Fraunhofer IFAM in Stade as part of the “SAMSON” project for recording and processing data in orchards can be mounted on any tractor via the three-point mount. This multi-sensor system contains the sensor technology for capturing camera images and precise GPS signals.
© Fraunhofer IFAM
The “sensor box” developed by Fraunhofer IFAM in Stade as part of the “SAMSON” project for recording and processing data in orchards can be mounted on any tractor via the three-point mount. This multi-sensor system contains the sensor technology for capturing camera images and precise GPS signals.

Core Competence Surface Technology

Core Competence Adhesive Bonding

Core Competence Automation and Digitalization