Department Automation and Quality Assurance in Production Technology

Department

Automation and Quality Assurance in Production Technology

The department "Automation and Quality Assurance in Production Technology", i.e. the Center for Lightweight Production Technology in Augsburg, develops holistic production chains for lightweight structures and assemblies. The aim is a seamlessly data driven and highly competitive full scale production technology to ensure a smooth transition from invention to innovation and industrialisation.

With unique large-scale facilities, the ZLP develops strategies to produce large CFRP components cost-effectively and in high quality. All process steps are investigated, integrated and reproduced on an industrial scale with the appropriate technical infrastructure.At the heart of the facilities at ZLP Augsburg is a robot-assisted research platform. This infrastructure is also available to customers in order to develop and validate production processes together with the DLR in a demand-oriented and flexible manner.

At the ZLP in Augsburg, DLR combines its expertise in structural and materials technology with that in the field of robotics and mechatronics for the production of CFRP components. It is thus pursuing the expansion of Germany's share in the value chain and ensuring this through sustainable technology development. In this way, it acts as a partner to industry, such as aerospace companies.

The ZLP site in Augsburg is located on the university campus in the Augsburg Innovation Park. The immediate proximity to the University of Augsburg ensures easy communication as the basis for sustainable cooperation between DLR and the university. The ZLP is also seen as an important element in the development of the economic structure of the Augsburg region. The "Aerospace Area Augsburg" is an ideal location, as there are important industrial partners in the aerospace industry within a radius of 50 kilometres. The establishment of the Centre for Lightweight Production Technology in Augsburg is being funded by the city, the Free State of Bavaria and the Federal Ministry of Economics and Technology.

Team Members in the Multifunctional Robot Cell
Image: 1/3, Credit:
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Multifunctional Robot Cell
In the multifunctional robot cell, six robots working together or alone are suspended from the ceiling and are flexible enough to be used for a range of projects.
Image: 2/3, Credit:
Cooperating robots
Automated handling of large dry-fibre CFRP blanks by cooperating robots for the production of an aircraft skin.
Image: 3/3, Credit:

Research Groups

Research Group Flexible automation systems

Tomorrow's production should be agile, easy and flexible. The focus of the group Flexible Automation Systems on increasing process and plant agility. The research addresses current challenges in the field of automation for aerospace applications.

Research Group Assembly and Joining Technologies

How can components for the aerospace industry be assembled automatically? The Assembly and Joining Technology team develops automated solutions for this problem. The portfolio includes the development of clamping technologies, fixtures and end effectors. Additional research topics are robot process and automation technology, tolerance and variant management, and overall process control.

Research Group Production Integrated Quality Assurance

Inline, of course – that's how the quality assurance of tomorrow should work. Thanks to the focus of the DLR Center for Lightweight Production Technology in Augsburg on the production-integrated real-time acquisition of manufacturing data in combination with specialised sensor systems for quality parameters adapted to the process, production can be continuously monitored and readjusted in good time before rejects even occur.

Research Group Processes and Automation

In the aerospace industry there is the need for new automated production solutions due to the comparatively low production rates of aircraft in combination with the high number of part variants. The Automation is one key element in reducing the production costs and to increasing part quality.

Research Group Technical Centre for Production Processes

The site in Augsburg has a comprehensive range of machinery and qualified skilled workers. In-house production is the cornerstone of greater sustainability and higher quality. From the development to the finished product, the complete value creation takes place in-house. The mastery of different process chains and technologies is a guarantee of success for the ZLP.

Research topics

Research topic

Hybrid structures

Hybrid designs that combine thermoset and thermoplastic materials offer a fascinating variety of properties and advantages.

Research topic

Thermoplastic technologies

ZLP Augsburg plays a pioneering role in the development and application of state-of-the-art materials for the aerospace industry, particularly in the field of thermoplastic fibre composite technologies. These innovative materials offer a multitude of advantages and open up new possibilities for the design and manufacture of aircraft and spacecraft.

Research topic

"Flextelligent" - Flexible & intelligent production

The artificial word Flextelligent (flexible & intelligent) describes a production system that can be used flexibly for different products with small batch sizes and, through the use of artificial intelligence, ensures that the data generated can be used to guarantee the quality of the products.

Contact

Prof. Dr.-Ing. Michael Kupke

Vice Director
German Aerospace Center (DLR)
Institute of Structures and Design
Pfaffenwaldring 38-40, 70569 Stuttgart

Prof. Dr.-Ing. Heinz Voggenreiter

Head of Institute
German Aerospace Center (DLR)
Institute of Structures and Design
Pfaffenwaldring 38-40, 70569 Stuttgart