Composite Systems, Inc.             

Aerospace, Automotive, Industrial and Marine Robotic Systems Integration

                                                                   Wind Energy                                                                        

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

 

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The world wide wind energy market is rapidly expanding with the demand for 'green energy'. Wind farms the world over continue to spring up. This has placed a great demand on blade manufacturers to produce both high quality and cost effective blades for the turbine manufacturers. Currently, most of the blade manufacturers continue to try to keep up with demand by bringing on more employees, which in turn, requires more space.

To address this growing problem, Composite Systems, Inc. (CSI) has developed 'Blade World', a gantry robot system with a wide variety of process hardware 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 blades being manufactured (10 - 100+ meters) and the variety in design and construction, these cells may be tailored to the customers specific requirements.

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 CSI's proprietary 'telescopic' z-axis, 3-axis gantry robot platform. (www.kukarobotics.com)

3-View of an 80 meter system

Note tool cribs for each robot                                                                                                                

Mobile Blade System

As the industry demands larger blades, transporting these becomes a serious economic issue. Therefore, CSI has designed a variant of the system to be mobile. This may be purchased or leased from CSI. This system provides for the manufacturing of the blades in a controlled environment at the wind farm site, thus eliminating the issue of transport altogether. Once the farm is complete simply relocate the system to the next farm. Materials are all that is required to be shipped in to the system.

System Capabilities and Options

  • 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

                               

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