The AFBOSS project, funded under the grant number 03SX499A, ran from 1 December 2019 to 31 March 2023 and was carried out by BaltiCo GmbH with contributions from the University of St. Petersburg and Kuka Robotics. The project aimed to develop an automated production line for boat and ship structures using the Stablegeverfahren, a novel weaving technique that promises higher optimisation potential than conventional methods. Dr. D. Büchler and Dr. Th. Elsken authored the final report.
Technically, the first work package focused on analysing interfaces, data volumes and interaction possibilities to enable process optimisation. This analysis led to the ability to automatically generate machine parameters, reducing manual configuration time. A virtual plant model was created, allowing computer‑based simulation of the entire production chain. The model was used to identify bottlenecks and to test process variations before physical implementation.
The core of the technical work was the optimisation of the Stablegeverfahren process. Three key areas were addressed: pocket geometry, pre‑laying of spars, and winding path design. Optimised pocket shapes were developed that balance a wide entrance for rapid robot access with a narrow interior to prevent yarn pull‑out and to produce compact knots. These new geometries improved the speed and stability of yarn deposition. The pre‑laying of spars was streamlined by redesigning the required hand‑over‑hand steps and by introducing mechanical aids that reduced operator effort. The winding path, which determines the sequence in which grid nodes are laid, was re‑optimised to minimise collisions and to reduce deformation of the structure. A new sequence algorithm was implemented that also includes early detection of potential conflicts, thereby improving overall build quality.
Sensor integration was selectively applied. In the tempering stage, continuous temperature monitoring was implemented, allowing real‑time control and recording of the temperature profile. In other stages, where sensor installation would be cumbersome, tablet‑based interfaces were trialled to provide operators with visual guidance and to capture manual feedback, although challenges arose from the resin‑heavy environment.
A representative solar‑boat structure was chosen for detailed simulation. The hull was modelled as a composite grid of CFK spars and GFK spars, and hydrodynamic optimisation was performed. The virtual model revealed issues with robot‑linear axis coupling, which required extensive software adjustments and consultation with the robot manufacturer. Despite these challenges, the simulation enabled early detection of manufacturing problems and guided design adjustments.
The project also explored dual‑robot collaboration. Two configurations were simulated: a side‑by‑side arrangement and a master‑assistant setup. The side‑by‑side configuration offered higher productivity, while the master‑assistant approach simplified coordination. Hardware solutions were evaluated, and a decision was made to procure a second robot rather than retrofit the existing system. A new support arm was integrated into the lay‑down head, adding two additional axes for precise positioning. Functional tests confirmed the concept but revealed occasional jerky motions that will be addressed in future iterations.
Software tools were adapted to accommodate new plate and hull geometries. Collaboration with the University of St. Petersburg began to optimise the grid structure through a three‑stage hierarchical approach, selecting appropriate optimisation algorithms. However, the project was interrupted by the COVID‑19 pandemic and later by the Ukraine war, which ultimately halted further progress.
Overall, the AFBOSS project delivered a comprehensive virtual model, optimised process flows, improved pocket geometries, a new winding path algorithm, selective sensor integration, dual‑robot coordination strategies, and adapted software tools. These results lay the groundwork for a fully automated production line capable of building complex composite boat and ship structures with higher efficiency and quality.