Robots Mainstream in Composites Manufacturing Automation for Aircraft Fuselage Stiffeners & Frames. sme.org/smartmfgseries

Transcription

1 Robots Mainstream in Composites Manufacturing Automation for Aircraft Fuselage Stiffeners & Frames sme.org/smartmfgseries

2 Timothy Olschewski Project Manager and Lead Engineer Orbital ATK sme.org/smartmfgseries

3 Overview Show several applications of robotic systems utilized within a composite manufacturing facility. Demonstrate robotic systems in use for the fabrication of uncured composite parts. Robots utilized in post-cure and machining of composite parts. Mainstream robotics can be a viable solution for a variety of composite manufacturing applications.

4 Orbital ATK Presentation Outline Orbital ATK Robot Applications Sabot Mold Compression Work Cell ABL Facility A350 Frames & Stringers ACCE Facility ASFM-Radial (4) ASFM-Linear (4) Automated Fiber Placement (1) Waterjet (3) Applications, Decisions & Integration 4

5 Compression Molding Capability SABOT Work Cell ABL Facility ton stamping presses 3 pick & place machines Pre-plied Carbon / Thermoplastic Sheets Pre-plied by a Kitting machine Pattern stamped to various shapes Robot collates stamped patterns into a mold Part is press molded to final shape Robot exchanges mold in / out of press Automated Stamping & Press Molding C176/5 5

6 Manufactured Using ATK patented, Automated Stiffener Forming Machines (ASFM) A350 Stringers and Frames ATK Builds Stringers For These Sections ATK Builds Frames For These Sections Frame Stringer Section Section Section Section 15 Stringers Frames C176/6 6 6

7 Automated Stiffener Forming (ASF) Build Stiffeners & Frames through automation: No fiber distortion/bridging No resin-rich zones, or trapped voids Eliminates multiple vacuum and/or hot pressure debulks prior to Autoclave cure The goal is for high volume production at reduced recurring cost At full rate we will be producing 25 miles of parts per day Material Forms Carbon Fiber 0 0, 45 0, 135 0, 90 0 The Process Automated Stiffener Forming Machine (ASFM) Build & form stiffener geometry ply by ply with out separate debulk process Orbital ATK Patented Process C176/7 7

8 Orbital ATK Robotics: ASFM Frames Fabrication Challenges: 4 material forms 0 0, 45 0, 135 0, 90 0 Limited footprint Limited # of SH s fit Cycle time between plies important 4 work cells in production Forming Process Supply Heads ASFM-R Video 1 Material Placed on Mold by SH Material Formed to Mold Cured Fuselage Frames C176/8 8 8

9 NEXT GEN Machine Orbital ATK Robotics: ASFM-L Stringer Fabrication Material Forms Forming Process Tool Direction ASFM-L GEN 3 Multiple material forms are placed & formed ply by ply as the stringer mold passes under the machine With increased tool lengths & additional material form requirements a next Generation machine (GEN 4) was needed. Machine platform only has 1 active material being applied to the mold during ply-by-ply fabrication Remove the non-active 3+ material forms from the base machine structure. Use a robot to remove the material (ply) no longer needed and replace with the next material (ply) needed PALLET CHANGING. Use a rack or storage stand to house multiple material forms not in use. ASFM-L GEN 4 KUKA Simulation C176/9 9

10 Robot Pallet Changing, Reduce Equipment Footprint, Increase Cycle Time Orbital ATK Robotics: ASFM-L In Production Benefits: Reduces footprint of equipment yet allows longer molds. Allows offline maintenance of material Supply Head(s). Allows reloading of material spent w/o stopping production. Allows for Spare material SH s Less linear table motion = increase cycle time. ASFM-L Video 1 ASFM-L Video 2 C176/10 10

11 Orbital ATK Robotics : ASFM-L Gen 5? Merge Aerospace Grade Robot from Automated Fiber Placement (AFP) with ASFM-Linear Forming Use robot for pallet changing process with multiple material forms, and Use robot for direct material placement on the molds Eliminate 1 head change function Increase machine cycle time. Images courtesy of Electroimpact C176/11 11

12 Orbital ATK Robotics : AFP Automated Fiber Placement (AFP) Commercially available robot Improved accuracy through secondary feedback encoders on all robot axis which control the position of the machine tool within an accuracy of ±0.3 mm Provides highly versatile work cell options Images courtesy of Electroimpact 12 C176/12 12

13 Robotic Tool Fixturing Saved customer $18M in Fixturing Cost Orbital ATK Robotics: Waterjet Part Fixturing High Speed Waterjet Water jet robotics holding fixture means no monuments and no Machining Restraint Fixture (MRF). Water jet robot bases saves minutes per part in MRF alignment, scanning and removal Video C176/13 Image courtesy of PAR Systems 13

14 Applications, Decisions & Integration Consider your application Does a robot make sense? Create decision matrix to evaluate pros / cons Cost $ o Integration can be 2x-3x of actual robot cost depending on size o Select qualified integrator(s). Investigate thoroughly. Footprint does it take more space than is utilized? o Will you be able to fence personnel out, or are they part of the process? What accuracy / repeatability does your process require? o Understand if your application has reversing loads. Joint movement = backlash not seen by control system o Do you require Aerospace grade robot higher accuracy through secondary feedback encoder use? o Will a standard crate robot be sufficient? Understand level of maintenance required C176/14 14

15 Questions C176/15 15

16 Contacts LEADERSHIP Steve Earl Vice President & GM Orbital ATK Aerospace Structures BUSINESS UNITS Steve Earl Vice President & Deputy General Manager Commercial Programs Bert Vanderheiden Military Andy Jackson Launch BUSINESS DEVELOPMENT Robert Murdock Orbital ATK Aerospace Structures COMMUNICATIONS Bryan Warren Orbital ATK Aerospace Structures 16

17 Aerospace Structures PO Box , MS YA15 Clearfield, UT