Purpose - The purpose of this paper is to provide a technical review of a new Bernoulli gripper development using computed fluid dynamics (CFD) modeling, and also to outline an appropriate independent testing method for validating and evaluating process capability in terms of automated thin wafer handling. The investigation has been carried out by a collaborative way of Festo and Fraunhofer IPA as a connecting link between applied research and industrial needs. Design/methodology/approach - Following an introduction, the paper first describes the basic development and fundamental principles of a gripper based on Bernoulli's law. The gripper was dimensioned and designed with the aid of CFD methods. The performance of the hardware was tested using extreme parameter settings while gripping thin, fragile workpieces. The performance of the gripper was tested from the aspects of shortest cycle times, positioning accuracy and air consumption and followed a manufacturer-independent design of experiments. A characterization of the gripping force generated during horizontal and vertical tension tests provides conclusive closed loop validation with regard to the gripper's air flow in the initial CFD model. Findings - Photovoltaic (PV) grippers are challenging components since the handling objects, 200-120 µmm thin crystalline silicon wafers with an area of 156 × 156 mm, are one of the most fragile parts as far as required handling speeds and cycle times are concerned. Originality/value - The paper provides a detailed technical review of a CFD application used in the development of a Bernoulli gripper and also describes a method for testing and evaluating PV grippers for industrial scale applications. The article presents the results of a close cooperation regarding an industrial development (Festo AG & Co. KG) and independent applied research (Fraunhofer IPA) for advanced product benchmarking and validation in a relatively young but dynamic and increasingly-automated PV industry
In this paper, the concept and the prototype realization of a novel reconfigurable small-footprint manufacturing system in a transportable container is presented. The containerized format enables transportation of the system to provide on-site manufacturing, enabling the benefits of localized service delivery without duplication of equipment at multiple locations. Three industrial product use cases with varying manufacturing and performance requirements were analyzed. All of the use cases demanded highly customized products with high quality in low production volumes. Based on their requirements, a general system specification was derived and used to develop a concept for the container-integrated factory. A reconfigurable, modular manufacturing system is integral to the overall container concept. Production equipment was integrated in the form of interchangeable process modules, which can be quickly connected by standard utility supply and control interfaces. A modular and self-configuring control system provides assisted production workflow programming, while a modular process chain combining Additive Manufacturing, milling, precision assembly and cleaning processes has been developed. A prototype of the container-integrated factory with reconfigurable process modules and control system has been established, with full functionality and feasibility of the system demonstrated. This paper describes how a comprehensive concept for a containerized mobile manufacturing system was developed, physically realized and demonstrated. 2.1 Decentralized Production Centralized production is replaced more and more by decentralized production and top-down methods by bottom-up synthesis [4, 5]. The adoption of production networks and distributed production is essential to the increase of competition and market globalization of manufacturing companies as well as Small and Medium Enterprise [6]. Matt et al. describe several approaches to cope with the challenges imposed by the changing production landscape [5]. Mobile, non-location-bound factories are identified as possible approach to realize geographically distributed production networks [5]. Such mobile production facilities require a high degree of flexibility in various dimensions, as well as the capability to be reconfigured in order to adapt the flexibility corridor to the continuously changing requirements of the market [5, 7].
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