Robotics firm works on innovative aerospace project

BLACK Country robotics firm KUKA Systems has collaborated with a leading aerospace group on a new research study into composite materials.

The Halesowen-based firm has worked with Bombardier Aerospace to devise an innovative robotic cell for laying up dry carbon fibre material.

The one-year programme, run by the Technology Strategy Board, has seen KUKA, together with other project partners Loop Technology and Güdel, form part of a wider consortium to look at ways of developing affordable composites manufacturing technologies.

The robotic cell developed during the project focused on its potential use in future wing production and is currently being trialled at Bombardier in Belfast. It aims to process dry carbon fibre material more quickly and efficiently than the existing method.

Depending on the size and profile of the wing structure, up to 200 plies may need to be put in place, which can be time-consuming due to the material’s flexible nature and tricky application technique.

The robotic cell aims to streamline the whole operation making the production process more efficient.

A camera checks the edges and weave angle of the wing throughout the process to ensure the plies are positioned properly and within the correct tolerances. An alarm is triggered if an error is detected.

Once the requisite number of sheets are in place, an ironing tool is attached to the robot arm and the panels fused together.

Gavin Campbell, director, design engineering and technology department, Bombardier Aerospace, said: “The cell was completed within the year and we are extremely pleased with its performance during this early development phase.

“With further development and trialling, we believe there is an opportunity for future application on aircraft wing programmes. The technology may also be attractive to others working in the field of composites such as the marine, automotive and sustainable energy sectors,” he added.

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