{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2025,11,15]],"date-time":"2025-11-15T10:31:36Z","timestamp":1763202696837,"version":"3.41.2"},"reference-count":25,"publisher":"Frontiers Media SA","license":[{"start":{"date-parts":[[2022,12,14]],"date-time":"2022-12-14T00:00:00Z","timestamp":1670976000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":["frontiersin.org"],"crossmark-restriction":true},"short-container-title":["Front. Robot. AI"],"abstract":"<jats:p>The production of large components currently requires cost-intensive special machine tools with large workspaces. The corresponding process chains are usually sequential and hard to scale. Furthermore, large components are usually manufactured in small batches; consequently, the planning effort has a significant share in the manufacturing costs. This paper presents a novel approach for manufacturing large components by industrial robots and machine tools through segmented manufacturing. This leads to a decoupling of component size and necessary workspace and enables a new type of flexible and scalable manufacturing system. The presented solution is based on the automatic segmentation of the CAD model of the component into segments, which are provided with predefined connection elements. The proposed segmentation strategy divides the part into segments whose structural design is adapted to the capabilities (workspace, axis configuration, etc.) of the field components available on the shopfloor. The capabilities are provided by specific information models containing a self-description. The process planning step of each segment is automated by utilizing the similarity of the segments and the self-description of the corresponding field component. The result is a transformation of a batch size one production into an automated quasi-serial production of the segments. To generate the final component geometry, the individual segments are mounted and joined by robot-guided Direct Energy Deposition. The final surface finish is achieved by post-processing using a mobile machine tool coupled to the component. The entire approach is demonstrated along the process chain for manufacturing a forming tool.<\/jats:p>","DOI":"10.3389\/frobt.2022.1021755","type":"journal-article","created":{"date-parts":[[2022,12,14]],"date-time":"2022-12-14T05:17:29Z","timestamp":1670995049000},"update-policy":"https:\/\/doi.org\/10.3389\/crossmark-policy","source":"Crossref","is-referenced-by-count":3,"title":["Scalable production of large components by industrial robots and machine tools through segmentation"],"prefix":"10.3389","volume":"9","author":[{"given":"Thorben","family":"Schnellhardt","sequence":"first","affiliation":[]},{"given":"Rico","family":"Hemschik","sequence":"additional","affiliation":[]},{"given":"Arno","family":"Wei\u00df","sequence":"additional","affiliation":[]},{"given":"Rene","family":"Schoesau","sequence":"additional","affiliation":[]},{"given":"Arvid","family":"Hellmich","sequence":"additional","affiliation":[]},{"given":"Steffen","family":"Ihlenfeldt","sequence":"additional","affiliation":[]}],"member":"1965","published-online":{"date-parts":[[2022,12,14]]},"reference":[{"key":"B1","doi-asserted-by":"publisher","first-page":"605","DOI":"10.1016\/j.cirp.2019.05.001","article-title":"Manufacturing of advanced smart tooling for metal forming","volume":"68","author":"Cao","year":"2019","journal-title":"CIRP Ann."},{"key":"B2","doi-asserted-by":"publisher","first-page":"89","DOI":"10.1016\/j.promfg.2017.11.010","article-title":"Design and optimization of a machining robot","volume":"14","author":"Denkena","year":"2017","journal-title":"Procedia Manuf."},{"key":"B3","doi-asserted-by":"publisher","first-page":"1373","DOI":"10.4271\/2011-01-2733","article-title":"High-accuracy robotic drilling\/milling of 737 inboard flaps","volume":"4","author":"DeVlieg","year":"2011","journal-title":"SAE Int. J. Aerosp."},{"article-title":"Miniaturized parallel kinematic machine tool for the machining of small workpieces","year":"2018","author":"Georgi","key":"B4"},{"key":"B5","doi-asserted-by":"publisher","first-page":"782","DOI":"10.1109\/70.897789","article-title":"Manufacturing feature recognition from solid models: A status report","volume":"16","author":"Han","year":"2000","journal-title":"IEEE Trans. Robot. Autom."},{"article-title":"Sheet metal forming simulation with elastic tools in ls-dyna","year":"2008","author":"Haufe","key":"B6"},{"key":"B7","unstructured":"Industrial automation systems and integration \u2014 physical device control \u2014 data model for computerized numerical controllers \u2014 Part 10: General process data2004"},{"key":"B8","doi-asserted-by":"publisher","first-page":"1629","DOI":"10.1007\/s12541-019-00187-w","article-title":"Robotic machining: A review of recent progress","volume":"20","author":"Kim","year":"2019","journal-title":"Int. J. Precis. Eng. Manuf."},{"key":"B9","doi-asserted-by":"crossref","DOI":"10.1109\/ETFA46521.2020.9211874","article-title":"A formal capability and Skill model for use in plug and produce scenarios","author":"K\u00f6cher","year":"2020"},{"key":"B10","doi-asserted-by":"publisher","first-page":"022075","DOI":"10.2351\/7.0000114","article-title":"Novel local shielding approach for the laser welding based additive manufacturing of large structural space components from titanium","volume":"32","author":"Kolsch","year":"2020","journal-title":"J. Laser Appl."},{"key":"B11","doi-asserted-by":"crossref","first-page":"214","DOI":"10.1007\/978-3-658-21300-8_18","article-title":"Hybrid-optimized manufacturing of load-bearing components by combining of conventional and additive manufacturing processes","volume-title":"Commercial vehicle technology 2018: Proceedings of the 5th commercial vehicle Technology symposium (CVT 2018)","author":"Ley","year":"2018"},{"article-title":"Swapit: A lightweight, modular industry 4.0 architecture","year":"2022","author":"L\u00fcnsch","key":"B12"},{"key":"B13","doi-asserted-by":"publisher","first-page":"17","DOI":"10.1016\/j.promfg.2017.11.003","article-title":"Machining of large scaled CFRP-Parts with mobile CNC-based robotic system in aerospace industry","volume":"14","author":"M\u00f6ller","year":"2017","journal-title":"Procedia Manuf."},{"key":"B14","doi-asserted-by":"crossref","first-page":"135","DOI":"10.1007\/978-3-642-23860-4_22","article-title":"Mobile systems for machining large work pieces","volume-title":"Enabling manufacturing competitiveness and economic sustainability","author":"Neugebauer","year":"2012"},{"key":"B15","doi-asserted-by":"publisher","first-page":"780","DOI":"10.4271\/2013-01-2292","article-title":"High accuracy articulated robots with CNC control systems","volume":"6","author":"Saund","year":"2013","journal-title":"SAE Int. J. Aerosp."},{"key":"B16","doi-asserted-by":"crossref","DOI":"10.1109\/ICMA.2010.39","article-title":"Multi-piece mold design based on linear mixed-integer program toward guaranteed optimality","author":"Stoyan","year":"2010"},{"key":"B17","doi-asserted-by":"crossref","DOI":"10.4271\/2017-01-2166","article-title":"Referencing strategies for high accuracy machining of large aircraft components with mobile robotic systems","author":"Susemihl","year":"2017"},{"key":"B18","doi-asserted-by":"publisher","first-page":"1388","DOI":"10.1007\/s11431-019-9510-1","article-title":"Mobile-robotic machining for large complex components: A review study","volume":"62","author":"Tao","year":"2019","journal-title":"Sci. China Technol. Sci."},{"key":"B19","doi-asserted-by":"publisher","first-page":"127","DOI":"10.1016\/j.promfg.2018.12.021","article-title":"Reconfiguring machine tool behavior via smart building block systems","volume":"28","author":"Uhlmann","year":"2019","journal-title":"Procedia Manuf."},{"key":"B20","doi-asserted-by":"publisher","first-page":"731","DOI":"10.1016\/j.cirp.2013.05.009","article-title":"Machine tools for large parts","volume":"62","author":"Uriarte","year":"2013","journal-title":"CIRP Ann."},{"key":"B21","doi-asserted-by":"publisher","first-page":"799","DOI":"10.1016\/j.cirp.2019.05.009","article-title":"Robots in machining","volume":"68","author":"Verl","year":"2019","journal-title":"CIRP Ann."},{"key":"B22","doi-asserted-by":"publisher","first-page":"389","DOI":"10.3390\/machines10050389","article-title":"Stiffness-oriented placement optimization of machining robots for large component flexible manufacturing system","volume":"10","author":"Xue","year":"2022","journal-title":"Machines"},{"key":"B23","doi-asserted-by":"publisher","first-page":"417","DOI":"10.1007\/s00170-016-9056-8","article-title":"Semantic approach to the automatic recognition of machining features","volume":"89","author":"Zhang","year":"2017","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"B24","doi-asserted-by":"publisher","first-page":"12","DOI":"10.1016\/j.cad.2018.03.006","article-title":"FeatureNet: Machining feature recognition based on 3D convolution neural network","volume":"101","author":"Zhang","year":"2018","journal-title":"Computer-Aided Des."},{"key":"B25","doi-asserted-by":"crossref","first-page":"47","DOI":"10.1007\/978-1-84800-380-4_2","article-title":"New concepts for structural components","volume-title":"Machine tools for high performance machining","author":"Zulaika","year":"2009"}],"container-title":["Frontiers in Robotics and AI"],"original-title":[],"link":[{"URL":"https:\/\/www.frontiersin.org\/articles\/10.3389\/frobt.2022.1021755\/full","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2022,12,14]],"date-time":"2022-12-14T05:17:36Z","timestamp":1670995056000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.frontiersin.org\/articles\/10.3389\/frobt.2022.1021755\/full"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2022,12,14]]},"references-count":25,"alternative-id":["10.3389\/frobt.2022.1021755"],"URL":"https:\/\/doi.org\/10.3389\/frobt.2022.1021755","relation":{},"ISSN":["2296-9144"],"issn-type":[{"type":"electronic","value":"2296-9144"}],"subject":[],"published":{"date-parts":[[2022,12,14]]},"article-number":"1021755"}}