Fiber Placement Robot

Products

Flexible, compact, versatile, our fiber placement system adapts easily to different geometries and ranges (IML,OML). It enables the manufacture of complex parts and is suitable for industrial applications as well as for the applications of research centers who can easily manage a high number of options. Its reliable and robust design meets the requirements of series production maintenance and high production levels are ensured through the speed of its movements. Precision and repeatability -basic criteria for the aeronautic market- are assured through a light manoeuvrable layup head. Lastly, this process is offered at an affordable budget combining quality, productivity and reliability.

The Coriolis fiber placement systems are supplied with the latest generation Kuka Quantec robots. These standard robots offer both a good rigidity and high precision, all combined with a high dynamic movement .

 

Coriolis' fiber placement robot
Coriolis' fiber placement robot at Compositic - Lorient
Description

The fiber placement system consists of a placement head, a creel and a tube for feeding the fibers. The creel provides all the necessary functions for unwinding the bobbins at high speed with low tension and enables swift ergonomic loading and unloading of the bobbins. The flexible pipes individually feed each fiber from the creel to the layup head avoiding all risks of twisting or damage to the fiber, while maintaining a low tension.

The system is compatible with pre-impregnated thermoset material certified by the aeronautic industry, but also with materials “of the future” such as dry fibers and pre-impregnated thermoplastics. This adaptation is made possible by a rapid change of the heating system. The unwinding, guiding and laying up system are already adapted to these three families of materials.

Due to the lightness and compactness of the Coriolis fiber placement heads, robot dynamic movements are exploited 100%, while minimizing efforts, and enabling maximum productivity combined with precision control.

The new Quantec Kuka or ABB offers improved movement combined with a increased repeatability and low consumption. These robots are perfectly adapted for placement heads of 1, 8 or 16 ¼’’ fibers.

 

Fact sheet - KUKA: QUANTEC KR210 R3100 Ultra

► KUKA KR210 R3100 standard robot.
► Ultra high resisting paint
► Measured robot option included: the robot has been measured by Coriolis and the values have been integrated into the controller.
► Absolute accuracy option included: software included in robot controller to compensate loads.
► Collision control option included: the robot stops if the loads exceed a certain value.
► Customer color to be defined except the arm.

Work
envelope
Dimensions (mm) Volume
A B C D E F G H 84,0m3
3 426 4 034 3 095 2 187 908 2 085 1 400 1 350

 

Maximum reach 3 100 mm
Rated payload 210 Kg
Supplementary load, arm 50 Kg
In-line wrist type IW 270 / 300
Maximum total load 260 Kg
Number of axes 6
Mounting position Floor, ceiling
Variant Foundry
Positionning repeatability +/- 0,06 mm
Weight (excluding controller), approx. 1 154 Kg
Temperature during operation +10°C to +55°C
Protection classification IP65 (Foundry variant wrist IP67)
Robot footprint 830 mm x 830 mm
Connection 7,3 kVA
Noise level < 75 dB

 

 Foundations

► Coriolis supplies a machine layout, and all the required information needed for the installation.

► Foundation requirements under the robot: concrete should be laid respecting the B25 (DIN 1045) and C20/25 (DIN EN 206—1:2001) standards.

► Surface tolerance: ±1 mm. This Offer is for installation of the robot at ground level, not above or below ground level.

► The Customer supplies ground foundation studies and works.

 

1-  Bedplate
2-  Concrete foundation
3-  Pin
4-  Hexagon bolt

 

Loads acting on the mounting base

 

 Force/torque/mass 

 Fv = vertical force

 Fvmax = 24 000 N

 Fh = horizontal force

 Fhmax = 16 000 N

 Mk = tilting moment

 Mkmax = 24 000 N

 Mr = torque

 Mrmax = 24 000 N

 Total mass for load acting
 on the mounting base

1 414 Kg 

 Robot

1 154 Kg 

 Total load (suppl. load
 on arm + rated payload)

260 Kg 

 

 

Fact sheet - ABB : IRB-6640

►ABB IRB-6640 / 2.75m / 205kg.standard robot

Measured robot option included: the robot has been measured by the supplier and the values have been integrated into the controller.

Absolute accuracy option included: software included in robot controller to compensate loads.

Collision control option included: the robot stops if the loads exceed a certain value.

ABB Robot specifications

Laying up aeronautic certified pre-impregnated thermoset materials

The Coriolis fiber placement system can lay all type of pre-impregnated thermoset material (from high to low grammage) currently used in fiber placement for making primary aeronautic structures. The particularity of its layup resides in the patented technique of guiding the fibers in the individually air conditioned tubes, removing all risks of degradation or material twist. Combined with a low tension, this guiding system simplifies the closed loop control of the fibers in both speed and tension, particularly at very high speed and during acceleration phases.

The polythene (or film separator) is rewound continuously on identical bobbins to the material bobbins. Thus, the loading/unloading of the film separator is done at the same time as that of changing the bobbins. This system eliminates all risks of contamination of the part by the separator.

Utilizing the pre-impregnated thermoplastic materials and dry fibers

A precursor in this domain, Coriolis processes more than ten years of knowledge in the implementation of this material in a fast growing market. The Coriolis fiber placement system has been designed from the start to be able to layup these materials, which require a guiding system and laying up under very low tension, so that the feeding follows the large radius of curvature.

The Coriolis fiber placement system can lay dry fibers coated with a resin to make RTM preforms or infusion or pre-impregnated thermoplastic fibers, and this, without requiring change or adaptation to the reeling, controlling, feeding and cutting systems. Only the heating system must be replaced by a high powered laser associated to a flexible layup roller, enabling continuous bonding at high speed during layup.

Creel - Specifications

►Tension regulated bobbin unwinding system
►Multiwinch® tension regulation system achieves a fiber tension close to 0 grams before entering the feeding tubes
►Film separator rewound continuously on an identical bobbin to that supplied for the fiber.
►Control sensors for the bobbin movements and fiber tension (must not be higher than the nominal value.)
►The system stops if:

  • A fiber is broken
  • A bobbin is empty
  • The fiber has not been re-fed to a new trajectory
  • A bobbin has a winding fault 

►Humidity measuring gauge
►Temperature control to 15°C
►Bar code reader for tracing the batches of material.
►Temperature recording
►Inflatable mandrel for rapid bobbin change
►Compatible for thermoset, dry fiber and thermoplastic material.
►Quickly adaptable for 3” type bobbins or the DIN250 type for thermoplastics

 

Fiber Feeding System - specifications

► The fibers are guided from the creel to the layup head inside the flexible tubes
► Individual feeding of each fiber in a tube
► The tubes can be cooled to 13°C
► A guiding device is supplied for manually feeding the first fiber into the empty tubes. During production, the fibers are always kept in the tubes. To restart production, a splice must be made from the new to the old fiber.
► Compatible for thermoset, dry fiber and thermoplastic material

 

 

Fiber placement head – specification

► Number of fibers : 1, 8, 16
► Width of the fiber : ¼’
► Each fiber can be individually cut and fed
► Weight of the head : between 45 and 90 kg
► Cutting and feeding speed : Maximum  0.6 m/s
► Repeatability of cutting and feeding : +/-2,5 mm
► Repeatability of the gap between the tapes : +2 - 0 mm
► Minimum length of the layup fiber on a flat surface : 100 mm
► Maximum placement speed : 1 m/s
► Maximum speed for a link path between 2 placements : 2 m/s
► Vertical compliance to absorb surface variations : +/-5 mm
► Compaction force can be set between 5 et 10N/mm of the width of the band for laying up on a honey comb, flexible insert and complex forms
► Rapid change of heating system (infra-red or laser)
► Modular design of the head enabling rapid dismantling and off line maintenance : Heating, guiding, cutting, feed and clamping, compaction module
► Head cooling system at 13°C
► Compatible for thermoset and thermoplastic prepreg material as well as dry fiber

 

Camera – Technical specifications

To improve the monitoring process, a camera can be supplied as an option: From his desk, the operator can view directly the fiber lay-up. Automatic recording can be provided to re-view some critical passages.

► Video camera mounted on the fiber placement head for lay up control,
► Lay up can be visualized from the HMI panel,
► Record system included and link to the traceability software,
► Movement detection capability