Workshops and foundries

For building our robot-systems we manufacture some components in our workshops and foundries. Here you can find some information about the following:

and especially:

Elektronic workshop

Contact person: Christian Schoo

In order to meet the special requirements of the robotics department, the electronics are in-house designed, constructed, and integrated. The electronics lab is equipped with devices for processing SMD-components for the greatest possible miniaturization. Furthermore, it offers a stencil printer to apply solder paste, an SMD pick-and-place system including a micro placer for processing almost all conventional components, a reflow oven as well as a number of soldering workplaces and microscopes. Here, electronic modules are assembled, tested, and integrated into the robotic systems. In addition, various measuring devices are provided for calibration and repair purposes.

Pictures

Integration of the electronic into a robot
Integration of the electronic into a robot
View on the workplace with robot in front
View on the workplace with robot in front
Microscope-workplace
Microscope-workplace
ESD-saved workplace
ESD-saved workplace
Soldering station
Soldering station
Electronic innards of a robot
Electronic innards of a robot

Mechanical workshop

Contact person: Karlis Vigulis

In our mechanical workshop we produce in the main prototypes and support-material (such as a sensor holder). Another task is the reparation and modification of our robot-systems. Those modifications include the adjustment of industrial products to special requirements.

The mechanical workshop possesses a solid basic configuration for mechanic treatment and a huge stock of standard parts and pre-products. For machining works we have a conventional milling machine (Wabeco F 1210 E high speed) and a screw machine in our equipment. They allow the prompt and precise manufacturing of the needed components. For the produce of smaller parts in batch fabrication we have a CNC milling machine (ISEL) available.

Whereas the manufacturing of prototypes, the repairing of robots and other smaller tasks are fulfilled in the workshop, jobs like batch fabrication of more complicated components are given to competent partners from industry and trade.

Pictures

Custom-made belt positioner, cutting, milling, drilling, bending, varnishing (project: Capio)
Custom-made belt positioner, cutting, milling, drilling, bending, varnishing (project: Capio)
Lathe for single and multi item production of and for prototypes, e.g. spacer rings (project: spaceClimber)
Lathe for single and multi item production of and for prototypes, e.g. spacer rings (project: spaceClimber)
Special item production for testing, here terminals of different materials (project: RimRes Sherpa)
Special item production for testing, here terminals of different materials (project: RimRes Sherpa)
Additional changes on prototypes (project: RimRes Module)
Additional changes on prototypes (project: RimRes Module)
Special item of full material (POM), here adapter for connection of Sherpa and Crex (project: RimRes Sherpa)
Special item of full material (POM), here adapter for connection of Sherpa and Crex (project: RimRes Sherpa)
Processing, production, modification of gearwheels (project: RimRes Sherpa)
Processing, production, modification of gearwheels (project: RimRes Sherpa)
Construction of a measurement module (project: SeeGrip)
Construction of a measurement module (project: SeeGrip)
Preventive maintenance and reparation of our Robotsystems (Project: SpaceClimber)
Preventive maintenance and reparation of our Robotsystems (Project: SpaceClimber)
Bending, lining up, fixation and adaption of cover material as well as grinding and varnishing (project: EO smart connecting car)
Bending, lining up, fixation and adaption of cover material as well as grinding and varnishing (project: EO smart connecting car)
Working up of breaks, scratches, bumps: filling in, cutting smooth and new Varnish (project: SpaceClimber)
Working up of breaks, scratches, bumps: filling in, cutting smooth and new Varnish (project: SpaceClimber)
Varnishing and preparing items made with the rapid prototyping plotter
Varnishing and preparing items made with the rapid prototyping plotter
 

Rapid Prototyping Plotter

Contact person: Felix Bernhard

Rapid Prototyping is a generative manufacturing process for the quick assembly of constructional elements from CAD Data. The printer uses the so-called “3D-Printing” process and is used for different purposes in the “Intelligent Structures for Mobile Robotic Systems” (iStruct) Project. The print head deposits a liquid plastic suspension layer by layer on a building table; UV-light hardens the construct to a solid.

Among others, mechanical demonstrators of spine, leg or foot concepts are made. Because of its precise print image, the printer is also used for sensor integration purposes. Generally, modern sensor elements are very small and have to be integrated very precisely into the surrounding structure.  For this purpose, the conventional assembly of construction parts is combined with the Rapid Prototyping process. In comparison to conventional manufacturing, complex structures can thus be produced quite easily, and different approaches can be promptly realized for comparing, evaluating, and optimizing.

The Rapid Prototyping Plotter
The Rapid Prototyping Plotter
mechanic spine study with plotted parts
mechanic spine study with plotted parts
toe-knuckle-models with plotted parts
toe-knuckle-models with plotted parts

Vacuum-Casting-Machine

Contact person: Felix Bernhard

The Vacuum-Casting-Machine is employed for the project “Intelligent Mobility (iMoby). With this machine, polyurethane casting components get degassed, mixed, and poured into their mold. The mold is built out of silicone or machine wax, depending on their application. Through the use of the so-called “Shape Deposition Manufacturing” process, functional structures of different hardenings can be created. This way, a structure may be provided with local material properties, for example, for making a special part of the structure adaptive or compliant. Actors and sensors can also be integrated into those structures.

Milled form
Milled form
The Vacuum-Casting-Machine
The Vacuum-Casting-Machine
Finished form
Finished form
© DFKI GmbH
last updated 06.10.2016
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