KRAKEN – Combining Additive and Subtractive Manufacturing Capabilities in an Ultra Large Scale Metrology Guided Robotic Manufacturing Cell

Paper #:
  • 2017-01-2134

Published:
  • 2017-09-19
Abstract:
Abstract: Imagine a COTS robot with the ability to perform a whole range of common manufacturing operations from milling and drilling to polishing and painting, on parts in excess of 10 meters, achieving the type of accuracies normally associated only with smaller components. Imagine it could work in a 20 x 6 x 5 meter space, and still leave the workshop floor 100% clear. This is MegaROB. Funded by the European Commission’s Factories of the Future (FoF) program, the €4.3 million international project created a first prototype, which can already complete functions such as milling, drilling, deburring, grinding, polishing, riveting, screwing, welding, coating and painting. MegaROB uses a conventional spherical robot mounted on an overhead crane to create a flexible automated platform that can be deployed for different tasks anywhere within its working volume, leaving the workshop floor completely clear. KRAKEN will take this amazing platform to the next level. This project will build on a hybrid approach merging the MegaROB subtractive machine (working area 20x6x3 meters) with both highly efficient metallic (10 kg/h rate) additive technologies as well as a novel non-metallic (180kg/h rate) additive technology. This paper will present both the technologies and the process that will allow KRAKEN to function on parts of any size with dimensional tolerances under 0.3mm and surface roughness under Ra 0.1µm. We will discuss how we plan to achieve at least a 40% reduction in time, 30% reduction in cost and 25% increase in productivity when comparing to the current additive and subtractive manufacturing process available today. We will discuss the plan to develop and demonstrate the efficiency and sustainability of this cost-effective hybrid manufacturing solution developing and constructing a functional machine concept using metal, resin, and combinations of both materials in industrially relevant environment for automotive and building industries.
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