Technologies

The machining of large components by huge machining centers is often a bottleneck in production. In this case, process control is spatially limited to the size of the plant and restricted in flexibility by the design principle. This is avoided by using mobile industrial robots (IR). Moreover, when using CNC-controlled robots, existing programs can continue to be used. The disadvantage of conventional IRs, however, is their lower accuracy compared to a processing machine, which has so far not allowed the required processing tolerances to be maintained.

Fraunhofer IFAM has now developed a novel solution for the dynamic improvement of the kinematics: the hybrid drive for industrial robots.

The combination of serial kinematics with external linear axes results in versatile and adaptable machine concepts for manufacturing, even for the production of large components.

INNOVATIVE SOLUTIONS FOR SUSTAINABLE COOLING TECHNOLOGIES | Magnetocaloric cooling systems offer industry a pioneering alternative to conventional compression refrigeration machines – technologically innovative, economically attractive, and ecologically sound. Instead of conventional refrigerants, these systems use the magnetocaloric effect: By making targeted changes to the magnetic field in specially developed materials, cold can be generated efficiently and in a controlled manner – without the use of fluorinated greenhouse gases.

Corrosion poses a serious threat to the longevity and functionality of metallic components. It is caused by environmental influences and contact with corrosive media, leading to enormous economic damage worldwide. In an industrialized nation, the direct costs of corrosion are estimated to be around three to four percent of the gross domestic product (GDP) annually. Early prevention is therefore crucial to preserving assets and minimizing costs.

On the way to optimize robot systems, an extraordinarily powerful software application for model-based calibration of industrial robots has been developed by Fraunhofer IFAM in Stade which enables high-precision robot use.

HIGH-PERFORMANCE COMPOSITES FOR RELIABLE ELECTROMAGNETIC COMPATIBILITY | Electronic systems are everywhere – from complex machine controls and sensor technology in Industry 4.0 to electric drives in vehicle construction. This also increases the risk of electromagnetic interference that can affect other devices or cause sensitive systems to malfunction. Compliance with electromagnetic compatibility (EMC) is therefore essential for the trouble-free functioning of devices and the reliability of sensitive electronic equipment. At Fraunhofer IFAM, we develop innovative functional composites for EMC protection.

HYDROGEN BARRIER COATINGS FOR TANKS, PIPELINES AND MORE | For hydrogen tanks and the like, metallic materials (e.g. steel or aluminum) are still predominantly used today, either as solid materials or as liners in polymeric materials, which constitute an enormous additional weight. In order that lightweight materials such as fiber reinforced polymers can also be used for fuel tanks etc., which do not provide a sufficient barrier to hydrogen permeation themselves, Fraunhofer IFAM is developing barrier coatings which strongly reduce the permeability of hydrogen and thus offer versatile possibilities for lightweight construction in the aerospace industry, but also in other areas.

We cover the complete value chain for the additive processes we have available at Fraunhofer IFAM – from the creation of 3D data models, through manufacturing, to final processing and inspection of the components.

Atmospheric pressure (AP) plasma can be used to clean, activate and coat surfaces efficiently and in an environmentally friendly manner. In industry, the process has now become established for pretreating surfaces prior to bonding, printing and painting processes in order to reduce the use of solvents (VOCs). In addition, the plasma-polymer nanolayers are used in production as corrosion protection, for environmentally friendly adhesion, for electrical insulation, or as a permanent hydrophobic release layer. Fraunhofer IFAM develops customized solutions using adapted processes and coatings with AP plasma for a wide range of applications.