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M.Sc. Daniel Kupzik

Akad. Mitarbeiter
Bereich: Maschinen, Anlagen und Prozessautomatisierung
Sprechstunden: nach Vereinbarung
Raum: 007, Geb. 50.36
Tel.: +49 721 608-42456
Fax: +49 721 608-45005
Daniel KupzikMub7∂kit edu

76131 Karlsruhe
Kaiserstraße 12

M.Sc. Daniel Kupzik

Forschungs- und Arbeitsgebiete:

  • Leichtbaufertigung
  • Robotik
  • Handhabungstechnik
  • Thermoplast


Allgemeine Aufgaben:

  • Betreuung der Vorlesung „Automatisierte Produktionsanlagen“



  • SmartBodySynergy zur Flexibilisierung der Fügezellen im Karosserierohbau
  • Graduiertenkolleg IRTG 2078 zur integrierten Verarbeitung von Lang- und Endlosfasermateialien


Versuchsstände: Roboterzelle für das vorrichtungsfreie Fügen



seit 01/2017

Wissenschaftlicher Mitarbeiter in der Gruppe Maschinen, Anlagen und Prozessautomatisierung am Institut für Produktionstechnik (wbk) des Karlsruher Instituts für Technologie (KIT)

10/2011 - 12/2016 Studium des Maschinenbaus am KIT




[ 1 ] Schwennen, J.; Kupzik, D. & Fleischer, J. (2017), „Development of a calculation model for load introduction elements integrated during frp sandwich structure manufacturing“. SAMPE Seattle 2017 : conference: May 22-25, 2017, exhibition: May 23-24, 2017, Washington State Convention Center, Seattle, Washington, Hrsg. Blohkowiak, K., S. 969-983.
Due to their high lightweight potential, FRP sandwich structures with foam cores are becoming increasingly important in the automotive industry. In order to accommodate local forces, load introduction elements are required. This work is part of a project in which the geometry is optimized for maximum load capacity, while taking into consideration the cost and the process restrictions. This paper deals with the creation of a suitable FEM model for investigating the effects of geometrical changes of the load introduction element on the load capacity. For this purpose, parameters of the foam and the insert material are determined experimentally. Subsequently, simulation examples are constructed using different solution methods, then compared and evaluated for applicability for an automatic optimization process. The result of the work shows that particularly three-dimensional models, which are explicitly solved, can deliver good results. The simulation results correspond very well to the experimentally determined tensile test curves.

[ 2 ] Kupzik, D. (2017), „Vorrichtungsfreies Fügen in smarten Rohbauzellen“, handling 6/2017, S. 36-37.
Zur Senkung der Anlaufkosten von Fahrzeugderivaten mit niedriger Stückzahl wird im Karosserierohbau in Werkstattfertigung das vorrichtungsfreie Fügen in den geometriebildenden Zellen eingeführt.

[ 3 ] Schwennen, J.; Kalbhenn, L.; Klipfel, J.; Pfeifle, J.; Kupzik, D. & Fleischer, J. (2017), „Evolutionary Optimization of the Failure Behavior of Load Introduction Elements Integrated During FRP Sandwich Structure Manufacturing“. Procedia CIRP, Hrsg. Roberto Teti, D. M. D., S. 410-415.
Due to their high lightweight potential, fiber-reinforced-plastics (FRP) sandwich structures with foam cores are becoming increasingly important in the automotive industry. To accommodate local forces, load introduction elements called inserts are required. A new type of insert is integrated into the sandwich panel during manufacturing. To accelerate the design and development process of these inserts, an optimization framework is developed based on the Abaqus CAE package and the Python programming language. An automated parametric nonlinear finite-element method (FEM) model is used to evaluate the performance of insert geometries. This model is integrated into an optimization routine based on a genetic algorithm. The population-based approach is very scalable through parallelization and shows accurate results within reasonable processing times.

[ 4 ] Kupzik, D.; Haas, S.; Stemler, D.; Pfeifle, J. & Fleischer, J. (2018), „Development of a manufacturing cell for fixtureless joining in car body assembly“. Tagungsband des 3. Kongresses Montage Handhabung Industrieroboter, Hrsg. Schüppstuhl, J. ., S. 22-30.
The integration of electric drivetrain components into the chassis of automobiles dramatically increases the variety of car body designs and calls for changes to the production processes. One approach is to replace the typical assembly line manufacturing process with a workshop production system, as has already happened in machining, where transfer lines have been replaced by flexible manufacturing systems. One requirement for this shift is the development of a flexible joining cell which can perform different stages of joining operations on different variations of a vehicle. One step in the development of such a cell is the replacement of mechanical positioning elements, used to define the parts’ relative positions before joining. In this work, the positioning of the components is done using a camera-based measuring system and a control loop to reorient the robots holding the parts. This paper describes how the system is developed and implemented in a demonstration cell.

[ 5 ] Kupzik, D.; Ballier, F.; Roller, T.; Coutandin, S. & Fleischer, J. (2018), „Development and evaluation of separation concepts for the controllable release of tacky prepreg from handling devices“. Procedia CIRP, Hrsg. Lihui Wang, S. 574-579.
The handling and layup of unidirectionally reinforced thermoset prepreg patches is currently a largely manual process. To reduce labor costs and increase part quality, automated handling of the material is desired. However, laying down the prepreg is challenging due to the tack of some materials. This paper investigates various modifications to an existing vacuum gripping system to enable a reliable separation process between the prepreg and the gripping system. The investigation focuses on the improvement of the integrated pneumatic blow-off mechanism, the development of a mechanical separation system and the application of different suction pads.

[ 6 ] Kupzik, D.; Ballier, F.; Lang, J.; Coutandin, S. & Fleischer, J. (2018), „Development and evaluation of concepts for the removal of backing foils from prepreg for the automated production of UD reinforced SMC parts“. Proceedings of the 18th European Conference on Composite Materials (ECCM18), Hrsg. European Society for Composite Materials (ESCM), S. 1-8.
Backing foil or paper needs to be removed from the raw material prior to the processing of Sheet-Moulding-Compound (SMC) or unidirectionally reinforced prepreg (UD-Tapes). In present automated production processes, this step is conducted after unrolling the raw material and prior to the cutting. In a process chain, which is conducted in the authors project, the backing foil needs to remain at the material after the cutting step. For these process chains, a method needs to be found to remove the backing foil from the material. In the state of the art, methods are shown to remove backing paper from prepreg. In this paper new methods are developed and tested for the removal of backing foil together with existing concepts. The main difficulty is the transition from backing paper to backing foil which has a higher tack to the material, is thinner and mechanically less strong. Concepts which are investigated use compressed air, mechanical forces or the stiffness of the foil. The application of compressed air is tested between foil and prepreg. Mechanical forces can either be introduced using grippers, brushes, friction to rubber or adhesive tape. The stiffness of the foil is used when removing it through bending the prepreg.