ACCIS Annual Conference Queen's Building, University of Bristol 15 September 2010
1
Why Dry Fibre Infusion? Cost Raw Material costs are lower
No pre-pregging charge Utilises high tow weights (12K & 24K) High speed large runs No refrigeration charge
Manufacturing costs are lower Potential for significantly higher deposition rate compared with prepreg High drape-ability
Raw Materials Easier to Recycle Performance The national Integrated Wing R&D Program demonstrated that, on aircraft wing components, performance could be equivalent to prepregs
2
Why Dry Fibre Automation? Cost reduction Current Aerospace standard dry fibre hand lay up
~15kg/hr
Current Aerospace standard tape laying
~15kg/hr
Estimated deposition rate with dry fibre automation
~60kg/hr
4 fold reduction in lay up time with additional cost savings Fewer lay up tools required at circa £1m each Less floor space required (building and ongoing maintenance)
Quality Accuracy -
Hand layup accuracy often dependent on operator skill and integrity
Repeatability -
Stage 1 trials using gantry robot proved high degree of repeatability
Quality control –
Vision system will check and record fibre orientation of each ply Edge of part checked, adjusted and verified
Delivery Flexibility -
Automated system quickly adaptable to any mould shape/type
Cycle time -
Reduction in layup time will reduce overall time to market
3
Technical Challenges •
Accuracy of positioning +/- 0.030 inch and +/- 5° fibre orientation
•
Material is permeable
•
Material can have single or multiple layers of fabric stitched together
•
Material can be NCF or Woven
Single layer UD fabric
•
Edge fraying
•
Drape
•
Wrinkles
Double layer +/- 45 NCF
Edge fraying of 5H
5 Harness Woven Fabric
Drape of UD fabric
Wrinkles in UD fabric
4
Background – Next Generation Composite Wing Development Stage 0 – Evaluation of selected grippers Stage 1 – Flat to Flat trials to evaluate accuracy, speed and acceleration
Speed and Acceleration
Drape
Accuracy
x mm
Accuracy
Speed
Reliability
Cost
Damage
Lift UD
Total
Gripper
(1 – 5)
(1 – 5)
(1 – 5)
(1 – 5)
(1 – 5)
(1 – 5)
( / 30)
A
4
3
1
1
1
0
10
B
2
5
3
5
5
0
20
C
4
5
4
4
5
0
22
D
5
5
5
5
4
5
29
5
Test & Risk Mitigation Programme
Demonstration of the Rapid Carbon Lay up solution on representative composite mould surfaces.
Automated Rapid Dry Carbon Fabric Production
Full Scale Component Trials
Dynamic Trials 3D Pick and Place of Dry Carbon Fabric (Proof of Concept)
Demonstration of grippers and gripper matrix capabilities on a full scale mould surface Evaluate the scalability of the design
iComp. TSB 50%
Ball Joint Gripper Fabric Connecting Rod
Pick and Place trials to evaluate accuracy of process when laying on a 3D, double curvature surface
Holding Cable
Dynamic Trials Pick and Place of Dry Carbon Fabric
Stage 1 Gripper matrix for flat trials allowing data to be gathered on process speed and accuracy Frame Gripper Spring Balance
Pick and Place trials to evaluate the accuracy, repeatability, speed and damage to fabric during „flat to flat „ trials
Down selection of of grippers using Pull off trials
NGCW TSB 25% INI 25%
6
The Objective: Full Scale Demonstration Cell “Cougar” 1.5m x 12m matrix
Matrix can rotate by up to 30° to account for fabric misalignment
Could deliver very large plies direct from roll
Individually controlled grippers Grippers free to move, relative to each other Stepper motors control the vertical displacement of grippers
Accuracy could be an issue for aerospace use More suited for marine and wind turbine applications Fitted to Gantry and/or auxiliary robots
Capable of forming all possible production curvatures All components lightweight to minimise running costs
8
Matrix – Preliminary Testing
Gripper Net
Test Frame
Carbon Fabric
Gripper Net
Gripper Matrix
Test Frame
Proof of Concept
Dynamic Test Cell (“Cub”)
Lifting 0.5m x 0.5m plies from a flat surface and manipulating to form a 3D double curve
Remotely lifting 1.5m x 1.5m flat plies and placing on a 3D double curvature tool
Grippers will be under manual control and will be adjusted using wire rope and clamps
Fully computer controlled, allowing a preliminary real world test of the control system 9
Vision & Tacking
Vision
Tacking
Camera and lighting system mounted on cooperating robots
Tacking head mounted on second pair of cooperating robots
Positional information used in feedback loop to increase the accuracy of ply layup
Robots will place tacks to hold ply in place after the matrix has retracted 10
Major Deliverables / Risks & Mitigation Major Deliverables The developed full scale automated cell will be used to demonstrate the layup of an aerospace (wing skin) and marine (hull section) item
Risks & Mitigation The relatively short duration of the project means the finish date may not be met Previous R&D carried out in the field (on NGCW)
Schedule has contingency plan to carry out demonstration at Gudel rather than Bombardier
Providing a lightweight manipulating system Automation suppliers included in consortium have expertise in weight reduction.
Reliable & high quality manufacture of complex components Vision systems for quality control Automated process – repeatable
Related issues e.g. NDE considered Addressed through other concurrent R&D (e.g. NGCW)
More than one market sector Aerospace & Marine directly involved 13
Progress Highlights @ Month 5 (31-Aug-10)
“Cub” 1.5m x 1.5m matrix
“Cub” Concept
“Cub” Reality ! 14
Progress Highlights @ Month 5 (31-Aug-10)
View of Underside of “Cub” Matrix
“Cub” Lifting a Ply
15
Composite Wing Development at Belfast
• Belfast is responsible for the outer wing components on the next generation of Bombardier aircraft • Successful completion of the iComposites project will ensure our competitiveness going forward.