SelfPaint-A self-programming paint booth

In this paper we present a unique Fraunhofer approach that aims towards a vision to automate the product preparation in paint shops by automatically generating robot paths and process conditions that guarantee a certain wanted paint coverage. This will be accomplished through a combination of state-of-the-art simulation technology, inline quality control by novel terahertz thickness measurement technology, and surface treatment technology. The benefits of the approach are a shortened product preparation time, increased quality and reduced material and energy consumption. The painting of a tractor fender is used to demonstrate the approach

Generating Optimized Trajectories for Robotic Spray Painting

In the manufacturing industry, spray painting is often an important part of the manufacturing process. Especially in the automotive industry, the perceived quality of the final product is closely linked to the exactness and smoothness of the painting process. For complex products or low batch size production, manual spray painting is often used. But in large scale production with a high degree of automation, the painting is usually performed by industrial robots. There is a need to improve and simplify the generation of robot trajectories used in industrial paint booths. A novel method for spray paint optimization is presented, which can be used to smooth out a generated initial trajectory and minimize paint thickness deviations from a target thickness. The smoothed out trajectory is found by solving, using an interior point solver, a continuous non-linear optimization problem. A two-dimensional reference function of the applied paint thickness is selected by fitting a spline function to experimental data. This applicator footprint profile is then projected to the geometry and used as a paint deposition model. After generating an initial trajectory, the position and duration of each trajectory segment are used as optimization variables. The primary goal of the optimization is to obtain a paint applicator trajectory, which would closely match a target paint thickness when executed. The algorithm has been shown to produce satisfactory results on both a simple 2-dimensional test example, and a non-trivial industrial case of painting a tractor fender. The resulting trajectory is also proven feasible to be executed by an industrial robot

Simulations of 3D bioprinting: predicting bioprintability of nanofibrillar inks

3D bioprinting with cell containing bioinks show great promise in the biofabrication of patient specific tissue constructs. To fulfil the multiple requirements of a bioink, a wide range of materials and bioink composition are being developed and evaluated with regard to cell viability, mechanical performance and printability. It is essential that the printability and printing fidelity is not neglected since failure in printing the targeted architecture may be catastrophic for the survival of the cells and consequently the function of the printed tissue. However, experimental evaluation of bioinks printability is time-consuming and must be kept at a minimum, especially when 3D bioprinting with cells that are valuable and costly. This paper demonstrates how experimental evaluation could be complemented with computer based simulations to evaluate newly developed bioinks. Here, a computational fluid dynamics simulation tool was used to study the influence of different printing parameters and evaluate the predictability of the printing process. Based on data from oscillation frequency measurements of the evaluated bioinks, a full stress rheology model was used, where the viscoelastic behaviour of the material was captured. Simulation of the 3D bioprinting process is a powerful tool and will help in reducing the time and cost in the development and evaluation of bioinks. Moreover, it gives the opportunity to isolate parameters such as printing speed, nozzle height, flow rate and printing path to study their influence on the printing fidelity and the viscoelastic stresses within the bioink. The ability to study these features more extensively by simulating the printing process will result in a better understanding of what influences the viability of cells in 3D bioprinted tissue constructs

A Lagrangian-Eulerian framework for simulation of transient viscoelastic fluid flow

A novel framework for simulation of transient viscoelastic fluid flow is proposed. The viscoelastic stresses are calculated at Lagrangian nodes which are distributed in the computational domain and convected by the fluid. The coupling between the constitutive equation and the fluid momentum equations is established through robust interpolation with radial basis functions. The framework is implemented in a finite volume based flow solver that combines an octree background grid with immersed boundary techniques. Since the distribution of the Lagrangian node set is performed entirely based on spatial information from the fluid solver, the ability to simulate flows in complex geometries is therefore as general as for the fluid solver itself. In the Lagrangian formulation the discretization of the convective terms in the constitutive equations is avoided. No re-formulation of the constitutive equation is required for stable solutions. Numerical experiments are performed of UCM and Oldroyd-B fluids in a channel flow and of a four mode PTT fluid in a confined cylinder flow. The computed flow quantities consistently converge and agree excellently with analytical and numerical data for fully developed and transient flow

A Backwards-Tracking Lagrangian-Eulerian Method for Viscoelastic Two-Fluid Flows

A new Lagrangian–Eulerian method for the simulation of viscoelastic free surface flow is proposed. The approach is developed from a method in which the constitutive equation for viscoelastic stress is solved at Lagrangian nodes, which are convected by the flow, and interpolated to the Eulerian grid with radial basis functions. In the new method, a backwards-tracking methodology is employed, allowing for fixed locations for the Lagrangian nodes to be chosen a priori. The proposed method is also extended to the simulation of viscoelastic free surface flow with the volume of fluid method. No unstructured interpolation or node redistribution is required with the new approach. Furthermore, the total amount of Lagrangian nodes is significantly reduced when compared to the original Lagrangian–Eulerian method. Consequently, the method is more computationally efficient and robust. No additional stabilization technique, such as both-sides diffusion or reformulation of the constitutive equation, is necessary. A validation is performed with the analytic solution for transient and steady planar Poiseuille flow, with excellent results. Furthermore, the proposed method agrees well with numerical data from the literature for the viscoelastic die swell flow of an Oldroyd-B model. The capabilities to simulate viscoelastic free surface flow are also demonstrated through the simulation of a jet buckling case

A Lagrangian-Eulerian simulation method for viscoelastic flows applied to adhesive joining

Viscoelastic flows are important for many industrial processes, such as adhesive joining, polymer extrusion and additive manufacturing. Numerical simulations enable virtual evaluation and product realization, which can support the design phase and reduce the amount of costly physical testing. However, such applications are challenging to simulate. Thus, efficient, robust and user-friendly simulation methods are needed. In this thesis, a Lagrangian--Eulerian simulation framework for viscoelastic flow is presented. The constitutive equation is solved at Lagrangian nodes, convected by the flow, while the momentum and continuity equations are discretized with the finite volume method. The volume of fluid method is used to model free-surface flow, with an injection model for extrusion along arbitrary nozzle paths. The solver combines an automatic and adaptive octree background grid with implicit immersed boundary conditions. In contrast to boundary-conformed mesh techniques, the framework handles arbitrary geometry and moving objects efficiently. Furthermore, novel coupling methods between the Lagrangian and Eulerian solutions as well as unique treatment of the Lagrangian stresses at the fluid-fluid interface are developed. Consequently, the resulting method can simulate the complex flows associated with the intended applications, without the need for advanced stabilization techniques. The framework is validated for a variety of flows, including relevant benchmarks as well as industrial adhesive joining applications. The latter includes robot-carried adhesive extrusion onto a car fender as well as a hemming application. The results agree with the available experimental data. As such, the research presented in this thesis can contribute to enable virtual process development for joining applications

A Lagrangian-Eulerian simulation framework for viscoelastic fluid flows

Viscoelastic fluids appear in various industrial applications, including adhesive application, additive manufacturing, seam sealing and parts assembly with adhesive. These processes are characterized by complex geometry, moving objects and transient multiphase flow, making them inherently difficult to simulate numerically. Furthermore, substantial amount of work is typically necessary to setup simulations and the simulation times are often unfeasible for practical use.In this thesis a new Lagrangian-Eulerian numerical method for viscoelastic flow is proposed. The viscoelastic constitutive equation is solved in the Lagrangian frame of reference, while the momentum and continuity equations are solved on an adaptive octree grid with the finite volume method. Interior objects are modeled with implicit immersed boundary conditions. The framework handles multiphase flows with complex geometry with minimal manual effort. Furthermore, compared to other Lagrangian methods, no re-meshing due to grid deformation is necessary and a relatively small amount of Lagrangian nodes are required for accurate and stable results. No other stabilization method than both sides diffusion is found necessary. The new method is validated by numerical benchmarks which are compared to analytic solutions as well as numerical and experimental data from the literature. The method is implemented both for CPU computation and in a hybrid CPU-GPU version. A substantial increase in simulation speed is found for the CPU-GPU implementation. Finally, an industrially suitable model for swirl adhesive application is proposed and evaluated. The results are found to be in good agreement with experimental adhesive geometries

An Immersed Boundary Based Dynamic Contact Angle Framework for Handling Complex Surfaces of Mixed Wettabilities

We propose a comprehensive immersed boundary-based dynamic contact angle framework capable of handling arbitrary surfaces of mixed wettabilities in three dimensions. We study a number of dynamic contact angle models and implement them as a boundary condition for the Continuum Surface Force method. Special care is taken to capture the contact angle hysteresis by using separate models for the advancing and receding contact lines. The framework is able to account for surfaces of varying wettability by making the contact angle dependent on the local boundary condition.We validate our framework using cases where glycerol droplets impact solid surfaces at low Weber numbers. We show how a truly dynamic contact angle model is needed for advancing contact lines and how a separate dynamic model is needed for receding contact lines. To test our framework for industrially relevant problems on a more complex surface, we simulate droplet impact on a printed circuit board. We show how the local surface properties control the final droplet deposition and that the framework is capable of handling adjacent surfaces of considerably different wettabilities

Optimisation of robotised sealing stations in paint shops by process simulation and automatic path planning

Application of sealing materials is done in order to prevent water leakage into cavities of the car body, and to reduce noise. The complexity of the sealing spray process is characterised by multi-phase and free surface flows, multi-scale phenomena, and large moving geometries, which poses great challenges for mathematical modelling and simulation. The aim of this paper is to present a novel framework that includes detailed process simulation and automatic generation of collision free robot paths. To verify the simulations, the resulting width, thickness and shape of applied material on test plates as a function of time and spraying distance have been compared to experiments. The agreement is in general very good. The efficient implementation makes it possible to simulate application of one meter of sealing material in less than an hour on a standard computer, and it is therefore feasible to include such detailed simulations in the production preparation process and off -line programming of the sealing robots

Automated Fibre Placement with In-Situ Ultraviolet Curing and On-The-Fly Resin Impregnation

Vehicle emissions contribute to up to one third of the world's air pollution [1]. Reducing vehicle weight is crucial to reducing these emissions. Composite materials offer high specific strength-to-weight ratios which make them ideal for lightweight applications; however, existing composite manufacturing is slow and expensive. Automated Fibre Placement (AFP) is a state-of-the-art composite manufacturing process but is limited by the low complexity of parts it can produce; the cost, size and speed of the actuation systems; expensive and sensitive material options; and numerous pre and post-processes required in order to complete a part. This research proposes a new and efficient composite manufacturing process that addresses these limitations by combining AFP technology with in-situ ultraviolet (UV) curing and on-the-fly fibre and resin impregnation (UVAFP). The body of this thesis focused on proving the process concept and building robust predictive models for the technology. It was proposed that reducing the size of the placement head would increase the capability of this technique to manufacture more complex parts. It was shown that by optimising the placement head clearance angle, placement head width and the compaction roller radius the minimum placement radius and arc length could be as small as 100mm and 90 degrees respectively. It was also demonstrated that industrial robots were sufficiently accurate and repeatable to act as placement articulators for AFP. The feed rate, path interpolation point filtering and spindle speed were optimised to achieve a path following accuracy of less than 0.042mm. By increasing the tension in the tow and compaction force, dry fibre tows were shown to be a suitably dimensionally stable replacement for expensive towpregs with minimal gaps and overlaps. Dry glass fibre tows and bulk vinylester resin impregnated on-the-fly was chosen as an inexpensive and versatile material system and consolidation approach for use in UVAFP. The material system was shown to have comparable mechanical properties to aluminium and steel but lighter with equivalent properties to composites manufactured by traditional techniques. Rapid impregnation times were demonstrated up to 2160 mm/sec. High intensity UV light curing eliminated the need for post process curing and shortened the cure time and increased layup speeds. When the UV light was applied in a ply-by-ply in-situ approach, the cure time was measured to decrease the current thermal cure cycle length by 43.75% and the degree-of-cure was increased by 1.3% (as measured indirectly by the interlaminar shear strength). By characterising the process parameters the effect on degree of cure and degradation could be controlled and predicted. A degree of cure in excess of 99% was achieved, providing equivalent material properties to traditional thermal cured composites while minimising peak exposure temperatures, thus reducing mass loss caused by thermo-oxidative degradation. UVAFP was demonstrated to be a viable composite manufacturing process capable of producing high quality components and addressing the limitations of current AFP systems. The technology was shown to address efficiency shortfalls and make composite manufacturing economical and accessible to vehicle manufacturers searching for manufacturing process solutions for lightweight