Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

The efficiency of a fuel cell is not only dependent on the stack, but also to a large extent on the turbocharger, which is responsible for providing the required airflow. Since the individual components, especially those of the rotor, are subject to high demands on manufacturing accuracy, it is crucial to ensure a precise and robust assembly. In order to achieve a scalable assembly process, this paper presents a method for a robot-based assembly of the rotationally symmetric components of the rotor. The assembly task has been reduced to the two essential problems: search and insertion. On this basis, a system was developed, which is able to learn the joining process independently and compensate for positioning inaccuracies with the help of reinforcement learning in combination with a position-controlled robot. The applied reinforcement learning strategy is based on the measurement data of a 6-axis force/torque sensor, with which the current contact state can be evaluated and a decision for the next step can be made. The experimental verification shows that an automation of the assembly process is possible with the proposed strategy. The robot is able to perform the search operation successfully, whereas limitations to the achievable accuracies of the insertion process could be found.

Billions of packages are automatically handled in warehouses every year. The gripping systems are, however, most often oversized in order to cover a large range of different carton types, package masses, and robot motions. In addition, a targeted optimization of the process parameters with the aim of reducing the oversizing requires prior knowledge, personnel resources, and experience. This paper investigates whether the energy-efficiency in vacuum-based package handling can be increased without the need for prior knowledge of optimal process parameters. The core method comprises the variation of the input pressure for the vacuum ejector, compliant to the robot trajectory and the resulting inertial forces at the gripper-object-interface. The control mechanism is trained by applying reinforcement learning with a deep Q-agent. In the proposed use case, the energy-efficiency can be increased by up to 70% within a few hours of learning. It is also demonstrated that the generalization capability with regard to multiple different robot trajectories is achievable. In the future, the industrial applicability can be enhanced by deployment of the deep Q-agent in a decentral system, to collect data from different pick and place processes and enable a generalizable and scalable solution for energy-efficient vacuum-based handling in warehouse automation.