Bachelor’s Thesis or Master’s Thesis
© BeckhoffTopic of the work:
The aim of this work is the development and implementation of an EtherCAT-based control architecture for precise process control in large-volume additive manufacturing. To this end, a modular system architecture is being designed that integrates the individual systems of a robot-supported production cell – in particular articulated arm robots, extruders and peripherals – into a central PLC control system. A major focus is on PLC programming with Beckhoff components using EtherCAT as a real-time capable fieldbus system. The coupled control of web movement and material feed is intended to enable targeted variation of the material deposit in order to reproducibly produce functionally or geometrically graded components. The work thus contributes to increasing process stability and flexibility in large-volume additive manufacturing.
The work is related to this research project:
The work is part of the Collaborative Research Center TRR 402 “DediGrad”. It researches production methods for the optimal combination of fiber composite and plastic technologies. The mechanical properties are to be specifically adjusted by local variation of the fiber orientation and the fiber volume content.
Objective:
The aim of the thesis is to develop an EtherCAT-based control architecture for synchronized robot and extruder control for the production of graded components in large-volume additive manufacturing.
Your task:
| For a Bachelor's thesis, you will work on the following tasks: | For a Master's thesis, you will work on the following tasks: |
| Research on control architectures and real-time communication in robot-assisted additive manufacturing | Research on control architectures and real-time communication in robot-assisted additive manufacturing |
| Conception of an EtherCAT-based system architecture for the integration of robots, extruders and peripherals | Conception of an EtherCAT-based system architecture for the integration of robots, extruders and peripherals |
| Implementation of the control logic in a Beckhoff PLC (TwinCAT) for synchronous control of robot movement and extruder | Implementation of the control logic in a Beckhoff PLC (TwinCAT) for synchronous control of robot movement and extruder |
| Development of an interface for coupling web parameters with extrusion parameters | Development of an interface for coupling web parameters with extrusion parameters |
| Production of test specimens to demonstrate simple graded components | Production of test specimens with systematically varied process parameters to demonstrate complex graded components |
| Analysis and evaluation of process stability, reproducibility and the resulting component properties |
Your profile:
- Interest in additive manufacturing
- Previous knowledge in the field of automation technology or robot programming is an advantage, but not mandatory – you will acquire the necessary basics in TwinCAT and EtherCAT as part of your work
- You value the combination of theoretical and practical work
- Independent, structured and autonomous work
- Interest in working on pioneering research projects
Preferred study programs:
- Mechanical engineering / industrial engineering, specialising in mechanical engineering
- Automation technology
- General mechanical engineering
- Computational Engineering Science (CES)
- Simulation Sciences
If you are interested in this exciting range of topics and would like to help shape the future of additive manufacturing, we will be happy to work together to develop a topic tailored to your needs. Feel free to contact me by e-mail, phone or in person at the IKV. I look forward to your message!