Aerospace

Composite Systems, Inc.

Aerospace, Automotive, Industrial and Marine Robotic Systems Integration

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

The aerospace market for both commercial and general aviation has progressed rapidly in the use of composite materials. With varieties of tapes, fabrics and cores provide the engineer with infinite engineering flexibility. However, current automated technology for rapid, accurate production is very limited. Tape laying machines (limited to 6.00" tape - currently) and fiber placement machines have provided a few large companies to benefit from these materials. But due to extremely high cost, these machines cannot provide a solution for the majority of manufactures.

Composite Systems, Inc. (CSI) has developed two new systems to provide cost effective solutions for both wing (all flying surfaces) and fuselage construction, namely 'Aerospace World' and 'Cylinder Cell'. These systems address key construction issues that are inherent to the fabrication of these structures. 'Aerospace World' is a gantry robot system with a wide variety of process hardware tooling within the cell. Depending upon production requirements, these systems may be set up with single or multiple gantries and/or robots per gantry. Because of the size of the parts being manufactured and the variety in design and construction, these cells may be tailored to the customers specific requirements. The CSI system does not employ columns about the perimeter of the cell. The gantry is self contained will all operational process hardware and runs on a 'recessed' floor rail system, providing total access to the cell environment.

The proprietary 'pass-thru' gantry design allows for the placement of tool cribs and material magazines about the cell perimeter. The 'twin-rail' bridge offers greater stability and payload, especially when the system employs the multi-stage Z-axis. The robot can access both tools and materials by being able to pass through the stanchions (legs) on either end of the gantry bridge. The cell may be set up to perform the construction of both the 'skins' of the blade as well as the internal 'grid' (ribs and spars) to facilitate 'parallel' construction operations.

The system will enhance the production and quality of layup in both 'open mold' and 'closed mold' processes, including RTM and VARTM, as the PFE technology lends itself to the placement of 'dry' materials. Furthermore, the system may incorporate either UV or IR curing technology, offering rapid and/or 'on-the-fly' curing during the layup regime.

KUKA K210 robot inverted on Composite System's, Inc. proprietary 'telescopic' z-axis, 3-axis gantry robot system. This system was developed in an effort to provide industry with a flexible 'platform' by which commercial robots of light to heavy payloads could be moved about or within a defined work envelope cost effectively. This system was built for the Canadian Research Council, Montreal Canada. (www.kukarobotics.com/)

The gantry system incorporates an adjustable 'balancing system' that can be configured to the robot and tooling the robot will utilize, including tool change during a specific work regime.

CSI gantry systems offer single and multi-tool work envelopes for a variety of industries. Aerospace and wind energy markets have been illustrated below.

Multi-gantry cell for paint stripping and re-painting of large aircraft employing the 'FlashJet' Coatings Removal System.

System Capabilities and Options

Gantry Cell sizes:
- 'X'-axis rails (floor) 150+ meters
- 'Y'-axis (bridge) 75+ meters
- 'Z'-axis (vertical) 45+ meters (Note: This is made possible by means of a proprietary 'telescopic multi-stage' counter balanced mast assembly system.)
Positioning Devices:
- CSI can provide multi-axis positioners that may work in the positioning of the blade plugs and molds within the cell.
- Head and Tail Stock Positioner (coordinated, simultaneous or indexing motion) in excess of 30,000 kg.
- Turret (rotating) floor positioner in excess of 30,000 kg. Diameters to customer specification.
Tool Crib:
- The tool crib may be set up with the following equipment with 'quick change' hardware for the robot:
- PFE Technology Please see Published Articles
  - As described the PFE is capable of performing layup in 'wet', dry and prepreg configurations.
- High Speed Spindle - for machining, routing, drilling, tapping - tool changer equipped
- Force Sensing Feed Back head - buffing, polishing, sanding, deburing, grinding - tool changer equipped
- Coatings Application:
  - Gelcoat System
  - Mold release agents
  - Primer / Paint
- Grippers:
  - These devices will be available to the robot(s) via 'quick change' hardware. They may be configured to supply core, imbeds, or hardware during the layup regime. These materials will be supplied to the cell by means of 'magazines' located about the cell perimeter.
Dust Extraction System:
- Dust from the various options selected above will be removed at the point of generation and contained for safe removal.
Integrated Curing Systems:
- UV, IR

'Cylinder Cell' offers a unique method of performing the layup of the fuselage as a single part.

Proprietary PFE "ID" Cylinder Cell" (mold cut for clarity)

Proprietary PFE "OD" Cylinder Cell"

The 'Cylinder Cell' system allows for the construction of products that may have round, oval, tapered oval, rectangular, square or polygon cross sections. Half sections may also be done by employing a 'counter balanced' positioner. The layup of composite material may be performed from inside (ID) the mold or outside the mold (OD), as indicated in the above illustrations. This is made possible because of the proprietary 'Z' axis (vertical) system moving the 'Linear PFE' device vertically, up and down, in concert with the 'feed' of the composite material from the Linear PFE device, to accommodate the desired cross section shape and fiber orientation.

The Linear PFE is comprised of PFE modules along the gantry bottom so as to provide a continuous layup on or within the mold. The gantry simply moves left or right to provide 'overlap' of the joints of the standard roll widths available that run along the length of the gantry. The system is capable of a 'spiral' layup as well due to the use of a PFE 'sled' that may run on one or both sides of the gantry beam. The PFE sled provides for rotation of the PFE so that angular and cross paths may be performed. Indexing the mold, positions the sled for the next pass. The mold is rotated about or under the 'Linear PFE Detachable Gantry System' (separates at mid-span) providing a layup layer of the complete part in one revolution. In this way the 'quadrant start point' of the layup will always be 'in gravity'. Upon completion of the part the gantry separates at mid-span and each half moves out of the mold at each end, respectively, to allow for removal of the part from the cell. With 'ID' systems the mold simply is spilt longitudinally. With 'OD' systems the mandrel is removed traditionally. The diameter and length of the Cylinder Cell is dictated by the part itself. Diameters and lengths in excess of 40' ft (12M) and 250'+ ft (76M), respectively, can be accommodated.

The proprietary 'ID' system lends itself, by design, to create a 'low pressure autoclave' from the mold itself. Composite Systems, Inc. can provide the complete superstructure for such molds and offers 'end caps' to the mold as options, to create the 'low pressure autoclave' environment. Combined with vacuum bagging operations the system lends itself nicely to many layup regimes.