Fraunhofer Group for Production
Fraunhofer Group for Production

Large Component Production through Segmentation

The production of large components, such as forming tools for the automotive industry or parts for wind turbines, poses enormous challenges for manufacturers. One challenge is the need for high-precision large machine tools with high investment costs and the associated low availability.
Large components can be segmented and produced on standard machine tools using the SWAP architecture, technologies and algorithms.
The SWAP-IT architecture automates this alternative process chain with methods for segmentation, process planning and demand- and load-based allocation of production orders to available machines. Furthermore, the solution provides a method for the subsequent joining of the segments to form the large component.

Current situation and challenges

  • Use of specialized single-purpose large machine tools
  • Increasing demand for flexibility (number of pieces, geometry)
  • Desire for efficiency increase, simultaneous operation
  • Demand for optimization of workload

Our project results

  • validated innovative process chain with machining of the segments, joining by collaborating robots, finish processing by temporarily coupled mobile machine
  • developed algorithms for optimal distribution of the machining task through autonomous segmentation
  • created self-description and control by OPC UA information models & methods and established connection to SWAP-IT architecture
  • developed demonstration of the entire process chain on the digital twin

Our vision

  • Minimization of the need for large machine tools through scalable linking of technology-flexible agents (machine tools with common workspaces, robots, mobile machine)
  • Increased flexibility in production through networking and suitable description languages
  • Optimization of workload through distribution of the machining task optimally adapted to the capabilities of the available field components
  • Enabling decentralized production of complex components (Manufacturing as a Service, Maas)

© Fraunhofer IML

Fields of application

  • Machining of large components (forming tools, wind energy industry, large engines)
  • Production of complex components with a high proportion of common parts and partial individualization   
  • Decentralized manufacturing with various processes