Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM

Adaptive gap measurement

Automated and precise determination of gaps for efficient gap filling, adhesive bonding, sealing and assembly processes

The gap between the joining surfaces of a CFRP frame and the fuselage shell is measured in order to optimally fill the gap during adhesive bonding.
© Fraunhofer IFAM
The gap between the joining surfaces of a CFRP frame and the fuselage shell is measured in order to optimally fill the gap during adhesive bonding.
The joining surfaces of the frame and the fuselage shell are measured with the Leica TScan, the point clouds are aligned with the respective CAD models and the gap is determined on this basis. The vectors projected from the frame show the gap in each area of the surface, ranging from 0.6969 mm to 1.6522 mm.
© Fraunhofer IFAM
The joining surfaces of the frame and the fuselage shell are measured with the Leica TScan, the point clouds are aligned with the respective CAD models and the gap is determined on this basis. The vectors projected from the frame show the gap in each area of the surface, ranging from 0.6969 mm to 1.6522 mm.

The measurement and understanding of existing gaps between component surfaces are essential in all joining and sealing processes in production. The precise characterization of the gaps contributes significantly to achieving optimal connections between the surfaces of the components to be joined. The Fraunhofer IFAM in Stade has developed a pioneering automated method that enables the precise recording of gaps and surface topographies in advance, thereby optimizing the subsequent individual compensation of the gaps. This advance not only improves the efficiency and quality of the joining, sealing or assembly process, but also significantly reduces the time required for manual adjustments. 
 

Precise gap measurement for efficient and high-quality assembly ...

In assembly processes that require the filling of gaps and the seamless joining of two components, the measurement of these gaps is crucial in order to

  • determine and apply the exact individual gap filling quantity,
  • avoid undesired stress development,
  • prevent damage due to corrosion and
  • reduce the previous labor-intensive, effortful, manual adjustments to component surfaces, which require specially qualified workers.


... especially for fiber-reinforced plastics (FRP)

With FRP, the deviations of the components to be joined from the target shape are often more pronounced and varied than with other materials, so that standardized conventional compensation methods are no longer sufficient. For this reason, the innovative developments of the Fraunhofer IFAM are of great benefit here in particular.


In one automated work step: from gap measurement to controlled, precise and individual gap compensation

To increase the efficiency and quality of the assembly process, the experts for Automation and Production Technology use a method for 3D surface measurement. Thanks to advanced laser-based measuring systems, the three-dimensional surface data of the components to be joined can be recorded and the spatial gaps between the surfaces precisely calculated, evaluated and quantified. The gap information obtained is then used to precisely fill these gaps with adhesive or sealing material, ensuring an optimum connection between the assembled components.

The gap data obtained serves as the basis for the immediate subsequent application of filler materials in the optimum application quantity at the individual location. In this way, they contribute to the optimization of the assembled structures.

Depending on the component and material type, filling is carried out by, for example,


Proven technology with future potential

Fraunhofer IFAM is continuously developing this technology to enable the measurement of a wide range of surface types with improved accuracy, precision and reliability. The method has already been successfully validated in various industrial applications, including

  • aircraft construction
  • rail vehicle construction
  • commercial vehicle construction
  • windturbine construction

In addition, the technology offers promising potential for numerous other sectors, such as medical technology and maritime industry.


Automation and robotics for large-scale structure production

Automation and robotics are two of the core competencies of Fraunhofer IFAM. The Stade branch develops practice-oriented technologies for the automated processing and assembly of large structures on a 1:1 scale.