From automation to 3D printing: Hardware and sensorics Department

At the beginning of the year, the Hardware and Sensors Department started a project in cooperation with the Fraunhofer Institute. It focuses on the development of sensors for the quality control of printing large 3D structures. But let's take a look at the department's previous major projects alongside this project. We interviewed the head, Tomáš Martinec.

Connecting 3D printing and artificial intelligence

The latest project of the department is currently working on adaptive multi-directional additive manufacturing based on artificial intelligence. This involves the development of advanced AI-based sensors for 3D printing of large-scale objects. The motivation is that customers such as automotive and aerospace companies are looking for more efficient methods of prototyping. Previously, entire blocks of aluminium had to be milled, which was not only costly but also extremely wasteful. 3D printing not only reduces costs, but also allows the material to be recycled, so that after printing and testing, the prototype can be milled and the material reused.

"Thanks to our cooperation with the Fraunhofer Institute, we have extruders, or printheads, which allow us to print from granulated materials instead of traditional filaments," says Tomáš Martinec, adding that this approach allows mixing of different materials and the production time is significantly shorter. "However, there can be errors during printing that we may not detect in time, as the process of precision large-format 3D printing takes tens of hours to days. CXI TUL's role in this project is precisely to continuously check the print," explains Tomáš Martinec.

"We are working on improvements to the sensor systems that will enable automatic correction of printing errors. Sensor data will be analysed using artificial intelligence. This task is being carried out by the Process Modelling and AI Laboratory at CXI TUL. Together with the project's principal investigator, Entry, we plan to implement this method directly into production. The German side is also planning to integrate it into real operation," says Tomáš Martinec.

History of the department since the establishment of CXI TUL

The project to combine 3D printing and artificial intelligence is underway. But what is the history of the hardware and sensors department since the creation of CXI TUL?  "The department is now divided into two key areas, industrial automation and measurement. Historically, we started as part of the Department of Software Engineering at the Faculty of Mechatronics, where mainly software was developed, but hardware projects were also created at the same time," Tomáš Martinec explains, adding that robotics has also been added with the move to the current department. Today, experts from the department work on a wide range of projects, from measuring water or air flow with a laser, which is handled by a team from the Physical Measurements Laboratory, to the development of industrial sensor systems. Tomáš Martinec recalled selected projects.

From artificial skins to robots

"One of our major industrial partners was Magna, where we participated in a large project to produce artificial leather using Slush Moulding technology for car dashboards," recalls Tomáš Martinec of his heart project. It was the focus of his dissertation. Slush moulding technology is extremely sensitive to temperature control, as the course of temperatures on the surface of the mould during the cycle affects the properties and quality of the resulting artificial leather. The solution was to precisely control the temperature and design an efficient thermocouple system that allowed for optimal heat distribution.

"But it wasn't just about temperature control. It was a complex solution for all sensors, including the hardware of the measuring modules. We were also involved in the development of the software that enabled precise monitoring and process control. In Russia, we even helped start up the entire line in Nizhny Novgorod in 2013, which was not only a technological but also a cultural experience. Why? We were looking for an air gun, for example. The locals advised us to go not to a tool shop, but to a flea market. We did, and no wonder. They say you can also buy a machine gun there," says Tomáš with a laugh.

Robots as precise as a watch

Another interesting project was a robotic assembly line for car glass. "We worked on a project for Sklopan, where we developed an automated system for installing rear-view mirrors on windshields. The line was equipped with Fanuc robots that used 2D and 3D camera systems to precisely manipulate the glass. The goal was to ensure that every part was identical, which was impossible to guarantee with manual work," says Tomáš Martinec of the project, which resulted in a fully automated process that met the strict standards of exclusive automakers.

Sensors that can see around the corner

"Another area we implemented was the inspection of paper air filters for heavy equipment. The filters have to meet strict standards. The customer required verification that none of the holes in the material were larger than the permitted limit. Traditionally, operators ensured this process by visually checking against a strong light," recalls Tomas. He adds that this was a project in which they designed a complete solution to implement the system into the line. They created a camera application that scanned the filter and used an advanced algorithm to look for abnormalities in the material that was connected to the production line.

Roboteam

"And then there's the unique wrapping technology that we designed and lab-tested. The wrapping technology is used for the production of parts for cars or airplanes, but it is also possible to produce blades for wind power plants. At the beginning, there is a lightweight core that can't stand up to anything on its own. But if we wrap it with special fibres at different angles and pour polymer (called matrix), it can be used, for example, as a reinforcement for the fifth door of cars that have to pass crash tests, or as a lightweight reinforcement for a helicopter window," says Tomáš. A key element of the experiments was the KUKA robots, which work in a Roboteam configuration and can synchronise movements. Four such robots can be found in the lab at CXI, making it possible for customers and partners to verify even very complex tasks before deploying them in industry.

"In our department, we may not be producing research for Science magazine, but we are doing something that has an immediate impact. We bring smart solutions directly into production. We develop sensors, actuators and programmable chips that take automation to the next level. They make production faster, more accurate and smarter," concludes Tomáš Martinec, whose innovations are taking automation to the next level.

 The picture shows Tomas Martinec with a piece created by the wrapping technology.