Composite Systems, Inc.             

Aerospace, Automotive, Industrial and Marine Robotic Systems Integration

                                                                   PFE_Technology                                                                        

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Composite Systems, Inc. provides "turn-key" solutions for the aerospace, automotive, industrial and marine industries worldwide....

 

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Composite Systems, Inc. has been working closely with aerospace and marine designers, engineers and manufacturers as well as composite materials suppliers, to develop advanced methods of composite material handling and layup. Our goal is to provide improved, cost effective, methods to produce quality, repeatable composite components and structures to the aerospace, automotive, marine and related industries.

With that in mind, Composite Systems, Inc. has developed and has patents pending and applied for worldwide regarding a new technology. 'Precision Feed Endeffector' (PFE) technology incorporates specially designed endeffector tooling that performs the layup of composite materials from the end of commercially available robots. This offers significant advantages over conventional ATL (automatic tape laying) machines in several ways. The PFE device can:

  • be set up to run pre-preg, semi-preg and 'dry' composite materials used in either conventional, RTM or 'wet layup' processes

  • perform layup of both unidirectional and woven materials in excess of 100M modulus

  • layup material from 2.00" (51 mm) to 60.00" (1524 mm) in width

  • be manufactured in 6.00" (152 mm) 'nominal' module increments at the factory as standard

  • custom configurations are available upon request - contact the factory

  • perform both ID (inside dimension) and OD (outside dimension) layup

  • perform inverted layup - material/process specific

  • perform 'de-bulking' during the layup regime - the suspension system provides for 100% contact with the surface of the mold

  • 'profile' (cut) the material edge or edges as it is being dispensed

  • remove the protective 'films' from the material as it is being dispensed

  • capture waste during the 'profiling' regime

  • dispenses and 'squeegees' resin during the layup (wet layup configuration)

  • layup material at speeds in excess of 1000 ipm (25.4 mpm) regardless of roll width - conditional to the material and robot system implemented

  • control the temperature of the material by incorporating (optional) 'non-condensing' refrigeration for the supply roll and thermostatically controlled 'warm air' (optional) when and if required

  • 'absorb' plug or molds containing concave, convex and/or spline surface geometry

  • layup material over various cores and foams

  • be equipped to dispense 'bagging' materials

Composite Systems, Inc. manufactures 'standard' track and gantry systems that may be configured with more than one robot. With the use of 'quick-change' wrists, these robot 'cells' may also include the following:

  • a 'tool crib' with multiple PFE devices, configured for a variety of material types, thicknesses, widths and bagging materials

  • 'grippers' to place core materials and 'imbeds'

  • portable UV and IR panels for curing

  • additional coordinated axis 'head and tail stock' positioners - to manipulate molds/plugs

With 'Cylinder Cell' systems, the PFE is comprised of multiple PFE modules connected together along the gantry bottom incorporating addition 'second tier' suspension to accommodate shape change a along the long axis (X) of the part. This works in concert with the (Z) axis, providing vertical travel to the tool.

(Note: Protective Covers Removed for Clarity)

 

 

Motoman UP200 robot with 24.00" (610 mm) PFE set up for prepreg material. System partially extended.

The provided video clips are of the PFE system performing layup of 24.00" (610 mm) woven carbon fiber prepreg material at 200" ipm (5080 mm/pm) over a honeycomb core.

Option 1

For those using Real Player 1 download the current version and view the video links below at a minimum 56k connection or higher.

Video of 0 degree layup.    Video of 90 degree layup.

Option 2

To watch the videos, a minimum of a 28.8k connection speed is required. You will also need to make sure that you have the latest Windows Media Player 9  for viewing from Windows 98, 98SE, Me, 2000 and XP,

Video of 0 degree layup.     Video of 90 degree layup.

 

PFE layup system conforming to concave surface geometry.

PFE system equipped with refrigeration equipment. (optional)

                                      

 

For more information please visit our Information page.                                 Composite Systems, Inc.- All Rights Reserved 2006/2007