Current Research Projects at the Institute of Assembly Technology

Assembly and Handling

  • Collaborative Assembly of Human and Machine
    Assembly is the final step in the process chain and therefore plays a key role in the value chain. The high cost and time shares of assembly in overall production reveal considerable potential for rationalisation, from assembly planning and preparation to assembly execution. For this reason, match is developing collaborative assembly systems and processes.
    Team: Sebastian Blankemeyer
    Year: 2015
  • Robot-assisted cooperative handling and assembly
    The handling and assembly of compliant and large-scale components is an important step in the process chain, especially with regard to fiber composite production. The problems that can occur when handling flexible components are their shape changes, which can lead to an undefined placement position. Furthermore, grasping with conventional grippers is often not possible.
    Team: Sebastian Blankemeyer
    Year: 2015
  • Underactuated handling systems
    Within the field of "underactuated handling systems" assembly systems with fewer actuators than degrees of freedom are being researched. The basic idea is to reduce the design effort and avoid the costs of actuated systems, where each degree of freedom is typically linked to a separate motor. The main topics are the structural synthesis of the orientation mechanism and the control of the highly nonlinear dynamics.
    Team: Tobias Recker
    Year: 2017
  • Handling of Hot-Forged Hybrid Components in the Process of Tailored Forming
    The CRC 1153 "Tailored Forming" aims to exploit the potential of hybrid solid components based on a novel process chain and to develop the required manufacturing processes. The match focuses on the development of functional modules for form-variable and function-integrated handling of components with temperatures up to 1250 °C.
    Team: Caner Ince
    Year: 2019
    Funding: DFG
  • CRC 1368: adhesive-based assembly processes in XHV-adequate atmospheres
    As part of the Collaborative Research Center 1368 "Oxygen-free production", the match deals with adhesive-based assembly technology in a technically oxygen-free atmosphere. The aim of the sub-project is to gain knowledge about the technical properties of bonded joints produced in an oxygen-free atmosphere and with deoxidized joining partners.
    Team: Sandra Gerland, Rolf Wiemann
    Year: 2020
    Funding: DFG
  • Active image-based feeding of small parts using aerodynamic chicanes
    A crucial component of automated assembly is the feeding device, which provides the handling device (e.g. industrial robot) with the components to be assembled in a defined position and orientation. In this project, methods for the flexible and efficient feeding of components are being researched with the help of image processing, AI and aerodynamic orientation modules.
    Team: Torge Kolditz
    Year: 2022
    Funding: DFG (German Research Foundation)
  • Strategies for piezo actuator-assisted disassembly of bolted joints
    The Collaborative Research Center (SFB) 871 "Regeneration of Complex Capital Goods" has been researching the scientific principles of regeneration since 2010, using civil aircraft engines as an example. The motivation is how complex components can be efficiently maintained and repaired in a resource-friendly way. The match focuses in the transfer project T16 on and develops novel strategies for gentle disassembly using the example of bolted joints.
    Team: Richard Blümel
    Year: 2023
    Funding: DFG
    Duration: 2,5 Years
  • CRC 1153: Flexible process chain for the resource-efficient production of tailored forming components
    As part of the Collaborative Research Centre 1153, new design, joining, forming, post-processing and testing processes for the production of hybrid solid high-performance components were developed and implemented. The aim of this sub-project is to link these individual processes into an automated overall process in order to validate the functionality of the processes in a continuous process chain and to produce reproducible samples.
    Team: Sebastian Blankemeyer
    Year: 2023
    Funding: DFG

Mobile Robotics and Robot Assisted Processes

  • Robot-assisted cooperative handling and assembly
    The handling and assembly of compliant and large-scale components is an important step in the process chain, especially with regard to fiber composite production. The problems that can occur when handling flexible components are their shape changes, which can lead to an undefined placement position. Furthermore, grasping with conventional grippers is often not possible.
    Team: Sebastian Blankemeyer
    Year: 2015
  • Underactuated handling systems
    Within the field of "underactuated handling systems" assembly systems with fewer actuators than degrees of freedom are being researched. The basic idea is to reduce the design effort and avoid the costs of actuated systems, where each degree of freedom is typically linked to a separate motor. The main topics are the structural synthesis of the orientation mechanism and the control of the highly nonlinear dynamics.
    Team: Tobias Recker
    Year: 2017
  • Autonomous Mobile Robotics
    Currently, the assembly of large products and systems requires the use of complex and bulky assembly equipment that can only be installed and operated at central production sites. The vision for the future is the use of a network of autonomous mobile robots that take over assembly or production directly at the target location. This solution requires coordinated cooperation between robots of different sizes.
    Team: Tobias Recker, Henrik Lurz
    Year: 2018
  • Handling of Hot-Forged Hybrid Components in the Process of Tailored Forming
    The CRC 1153 "Tailored Forming" aims to exploit the potential of hybrid solid components based on a novel process chain and to develop the required manufacturing processes. The match focuses on the development of functional modules for form-variable and function-integrated handling of components with temperatures up to 1250 °C.
    Team: Caner Ince
    Year: 2019
    Funding: DFG
  • TRR 277 Additive Manufacturing in Construction
    While productivity in the manufacturing industry increased linearly in most areas, this value has stagnated in the construction industry for about 50 years. The reason for this is the high manual effort required to create complex formwork elements. The aim of TRR 277 is to avoid this by using additive manufacturing processes. An interdisciplinary approach is being pursued, taking into account planning, production and assembly.
    Team: Lukas Lachmayer
    Year: 2020
    Funding: DFG
  • Assembly station based on a magnetic levitation system
    To achieve a cost efficient production of optical components or photonic integrated circuits, PhoenixD is following the approach of implementing an production matrix based on a levitated transport system. The goal is to use the mover not only for the transport between stations, but also as a functional unit during the stations.Therefor the match investigates and develops an integrated assembly station.
    Team: Lars Binnemann
    Year: 2021
    Funding: DFG (PhoenixD)
    Duration: 4 Jahre
  • Active Suction Device for Deep-Sea Applications (ASDDSA)
    In a collaboration with the GEOMAR (Helmholtz Center for Ocean Research Kiel), the match team is researching the development of a soft robotic system that can be used in the deep sea to take sediment samples. The aim is to develop a lightweight, cost-effective and pressure-neutral actuation system to replace the hydraulically actuated titanium manipulator currently in use and reduce the overall costs of deep-sea sediment sampling.
    Team: Jan Peters, Cora Maria Sourkounis
    Year: 2022
    Funding: DFG
  • Strategies for piezo actuator-assisted disassembly of bolted joints
    The Collaborative Research Center (SFB) 871 "Regeneration of Complex Capital Goods" has been researching the scientific principles of regeneration since 2010, using civil aircraft engines as an example. The motivation is how complex components can be efficiently maintained and repaired in a resource-friendly way. The match focuses in the transfer project T16 on and develops novel strategies for gentle disassembly using the example of bolted joints.
    Team: Richard Blümel
    Year: 2023
    Funding: DFG
    Duration: 2,5 Years
  • Digital planning and automated production of buildingintegrated photovoltaics (DIGI-PV)
    The goal of the DIGI-PV project is to reduce barriers to the large-scale use of PV technology in order to open up significantly more façade areas for energy use. For this purpose, automated processes and tools are being developed that enable planners, producers and users to implement efficient and cost-effective processes and support them along several phases of the product life cycle.
    Team: Sebastian Blankemeyer, Jessica Schönburg
    Year: 2023
    Funding: BMWK

Precision Assembly

  • Precision Assembly
    Whether sensors, pacemakers or watch movements: wherever parts have to be assembled very precisely, conventional robots and corresponding peripherals reach their limits. In this area, match is investigating new solutions and strategies to implement reliable and economical precision assembly processes.
    Team: Martin Stucki, Rolf Wiemann, Niklas Terei, Lars Binnemann
    Year: 2018
    Funding: basic funding
  • PhoenixD
    The PhoenixD Cluster of Excellence brings together various specialist domains from optical design, optical simulation and optical production with the aim of developing intelligent, integrated and adaptive optical systems. In this project, match takes on precision assembly tasks and focuses more intensively on fully process-integrated component alignment via self-assembly and the development of innovative, self-optimising assembly concepts.
    Team: Martin Stucki, Rolf Wiemann, Niklas Terei, Lars Binnemann
    Year: 2019
    Funding: DFG
  • Self-Assembly
    This research area is concerned with the development of self-assembling or self-positioning systems. The specific design creates energetic potentials that effect the components and thus pull them to the assembly position. Handling of the individual components is no longer necessary, which enables new applications, such as non-contact assembly.
    Team: Martin Stucki
    Year: 2019
    Funding: PhoenixD, DFG
    Duration: 7 years
  • Assembly of photonic integrated circuits
    The Cluster of Excellence PhoenixD pursues the goal of integrating conventional and complex high-performance optics into intelligent, miniaturised and adaptive optical systems. In this context, match is researching novel concepts and processes for the micro-assembly of optical systems.
    Team: Niklas Terei
    Year: 2021
    Funding: DFG (PhoenixD)
  • Assembly station based on a magnetic levitation system
    To achieve a cost efficient production of optical components or photonic integrated circuits, PhoenixD is following the approach of implementing an production matrix based on a levitated transport system. The goal is to use the mover not only for the transport between stations, but also as a functional unit during the stations.Therefor the match investigates and develops an integrated assembly station.
    Team: Lars Binnemann
    Year: 2021
    Funding: DFG (PhoenixD)
    Duration: 4 Jahre

Soft Robotics

  • Coherent Methodology for Modelling and Design of Soft Material Robots – The Soft Material Robotics Toolbox (SMaRT)
    Robots made of soft materials offer a high degree of flexibility. The compliance of the material leads to a high level of adaptability that classic robot systems do not offer. In the project SMaRT ("Soft Material Robotics Toolbox"), match is conducting research together with the Institute for Mechatronic Systems (imes) and the Institute for Dynamics and Vibrations (IDS) on a coherent methodology for modeling and designing soft material robots.
    Team: Mats Wiese
    Year: 2019
    Funding: DFG
  • Soft Material Robotic Systems
    Soft Material Robotic Systems (SMRS) are flexible robots made of soft materials such as silicone or elastomers. Unlike conventional robots, they can adapt to complex environments and utilize pneumatic, hydraulic, or even chemical actuators for movement. SMRS are frequently utilized in areas where traditional robots are unsuitable due to their rigidity or limited flexibility, such as in medical rehabilitation, food production, or underwater research.
    Team: Ditzia Susana Garcia Morales, Mats Wiese, Jan Peters, Cora Maria Sourkounis
    Year: 2019
    Funding: DFG Priority Programme
  • Active Suction Device for Deep-Sea Applications (ASDDSA)
    In a collaboration with the GEOMAR (Helmholtz Center for Ocean Research Kiel), the match team is researching the development of a soft robotic system that can be used in the deep sea to take sediment samples. The aim is to develop a lightweight, cost-effective and pressure-neutral actuation system to replace the hydraulically actuated titanium manipulator currently in use and reduce the overall costs of deep-sea sediment sampling.
    Team: Jan Peters, Cora Maria Sourkounis
    Year: 2022
    Funding: DFG

Digital Production and Autonomous Systems

  • Autonomous Mobile Robotics
    Currently, the assembly of large products and systems requires the use of complex and bulky assembly equipment that can only be installed and operated at central production sites. The vision for the future is the use of a network of autonomous mobile robots that take over assembly or production directly at the target location. This solution requires coordinated cooperation between robots of different sizes.
    Team: Tobias Recker, Henrik Lurz
    Year: 2018
  • PhoenixD
    The PhoenixD Cluster of Excellence brings together various specialist domains from optical design, optical simulation and optical production with the aim of developing intelligent, integrated and adaptive optical systems. In this project, match takes on precision assembly tasks and focuses more intensively on fully process-integrated component alignment via self-assembly and the development of innovative, self-optimising assembly concepts.
    Team: Martin Stucki, Rolf Wiemann, Niklas Terei, Lars Binnemann
    Year: 2019
    Funding: DFG
  • TRR 277 Additive Manufacturing in Construction
    While productivity in the manufacturing industry increased linearly in most areas, this value has stagnated in the construction industry for about 50 years. The reason for this is the high manual effort required to create complex formwork elements. The aim of TRR 277 is to avoid this by using additive manufacturing processes. An interdisciplinary approach is being pursued, taking into account planning, production and assembly.
    Team: Lukas Lachmayer
    Year: 2020
    Funding: DFG
  • Assembly of photonic integrated circuits
    The Cluster of Excellence PhoenixD pursues the goal of integrating conventional and complex high-performance optics into intelligent, miniaturised and adaptive optical systems. In this context, match is researching novel concepts and processes for the micro-assembly of optical systems.
    Team: Niklas Terei
    Year: 2021
    Funding: DFG (PhoenixD)
  • IT security in the deployment of 5G in production ecosystems (5GProSec)
    The aim of the research project is to systematically identify and eliminate potential attack vectors and unintentional disruptions when using 5G, especially in production. The focus is on both the technical and non-technical aspects of attack vectors. The methods developed are intended to reduce barriers to the use of 5G in companies and dispel security concerns.
    Team: Henrik Lurz
    Year: 2023
    Funding: BSI
  • Digital planning and automated production of buildingintegrated photovoltaics (DIGI-PV)
    The goal of the DIGI-PV project is to reduce barriers to the large-scale use of PV technology in order to open up significantly more façade areas for energy use. For this purpose, automated processes and tools are being developed that enable planners, producers and users to implement efficient and cost-effective processes and support them along several phases of the product life cycle.
    Team: Sebastian Blankemeyer, Jessica Schönburg
    Year: 2023
    Funding: BMWK
  • CRC 1153: Flexible process chain for the resource-efficient production of tailored forming components
    As part of the Collaborative Research Centre 1153, new design, joining, forming, post-processing and testing processes for the production of hybrid solid high-performance components were developed and implemented. The aim of this sub-project is to link these individual processes into an automated overall process in order to validate the functionality of the processes in a continuous process chain and to produce reproducible samples.
    Team: Sebastian Blankemeyer
    Year: 2023
    Funding: DFG