The second test run at the prototyping workshop ECW, Zeltweg, aimed on automatic manufacturing processes for the production of a timber frame wall. Based on the requirements of traditional timber production companies the CAD-CAM interface to the robot cell was tested on a number of crucial production steps.
Optimal cutting parameters for gypsum board and OSB were assessed with respect to the use of circular saw blades and milling heads. The test results showed for both cutting systems accuracy, cutting speed and panel displacement was within the predefined manufacturing tolerances.
The automatic stapling of gypsum and OSB board with a heavy-duty gun tacker posed specific challenges to the power control, tacking speed, staple spacing and displacement of unfastened boards. For both panel types, the tacking power could be adjusted to gain the right staple depth. For the OSB panel protruding staples were not observed, whereas for gypsum boards a too deep penetration of the surface layer was avoided. Furthermore, the tacking did not affect the position of adjacent unfastened panels.
The production steps drilling of socket outlets and notching of panels were tested separately for gypsum and OSB board before applying each layer to the timber frame. The results showed that the achieved processing and positioning accuracy were within the defined tolerances. Both layers matched perfectly to each other and the stacking accuracy of the robot-based system met the expectations.
In the next test run (scheduled for October 2017) all processing steps will be integrated and the whole cladding of the timber frame wall will be done automatically by an industrial ABB robot.
Video test run: