This case originates from the composites industry of automotive sector and more specifically VDL Fibertech Industries B.V which is part of the VDL group and one of the oldest composite companies in the Netherlands. The VDL case will address challenges in the lay-up manufacturing process of large automotive panels. Currently, this process is consisted by a series of manual handling operations of flexible Glass Fiber (GF) textiles in addition to foam blocks. The complete workflow takes place on lay-up moulds where all types of GF textiles and foams are positioned according to manufacturing process specifications before resin infusion. Given the geometry of the panels, the size of the layup textiles and foams involved in the process is large and difficult to be manipulated. Moreover, the dimensions of the mould itself limit effortless operator access to all areas. Subsequently, fluctuations on performance indicators (e.g. cycle time, production rate, quality, etc.) in addition to ergonomic issues may occur.
MERGING will tackle those issues by developing and integrating a dexterous handling system able to perform grasping, manipulation and placement of textiles and foam blocks. The envisioned solution proposes a hybrid cell where humans and robots collaborate in fenceless environment. LMS, CEA and AIMEN, helped by CASP and OPTEAMUM, will elaborate the robotic system installation layout, and support VDL in the implementation of the robot and gripper. CASP will fine tune the control and communication software of the robot to the specificities of VDL use-case. EPFL will adapt the electro-adhesive gripping device to enable the manipulation. IPC will analyze the gripper / flexible materials (fibres, textile, foams, …) interactions and provide support to the products quality analysis.
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