CompositesWorld
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NEWS 35 CompositesWorld.com Reconfigurable Tooling & Fixtures Developed by TETRAFIX AB (Kungälv, Sweden), the TFS unit pickups are modular and may be equipped with numerous end- effectors, offering a solution with flexible features for a variety of applications and industries. ey are used as coordinate measuring machine (CMM) fixtures in automotive applications to double-check the dimensions of the manufactured part vs. the digital design and also in assembly trials to see if components mate as designed. Although they are completely adjustable and 6DoF-configurable, when fixed, TFS units have the same stiffness and strength as solid aluminum. "We work with TETRAFIX a lot," says Helgosson. "We've taken technology from automotive and are adapting it for aerospace." e final elements in the Prodtex Toolbox are Flexapods and Hexapods. Both are Stewart Platform 6DoF posi- tioning devices, which means they have a parallel top and bottom plate connected by six adjustable legs. Flexapods were origi- nally developed with SAAB Aeronautics. "We needed a 6DoF positioning device that could be adjusted with an external metrology system," Helgosson explains. Although Hexapods have been around since the 1960s, says Helgosson, "most were either too accurate and expensive, or not accurate enough." us, Prodtex devel- oped its own version, called Flexapods, which are manually adjusted to ±200 mm and include a tool-changing unit mounted on the top plate to attach pickups or metrology devices. For the LOCOMACHS project, Prodtex developed automated versions with electrically actuated legs, essentially bespoke Hexapods that use external metrology to deliver aerospace positioning accuracy at an affordable cost. Less cost, time, shimming & risk Given the flexibility afforded by digital metrology and the Prodtex Toolbox, tooling fixtures can be adjusted or config- ured automatically to cope with design changes or product variations. "It also enables live fixtures," says Helgosson, such as the lower cover fixture for the Lean Assembly Wing Box (LAWiB) demonstrator in the LOCOMACHS project. "e pickup locations in live fixtures can be tweaked even after the tooling fixture is built," Helgosson explains, "because we can precisely realign and recalibrate them." Hexapods were used as adjustable pickups in the lower cover fixture, developed for the LAWiB, which Prodtex designed in only 20 minutes. It was delivered in four weeks and construc- tion was completed in a mere three days. "It only had eight pickups," he concedes, "but proves the potential of reconfigurable tooling. We wanted to challenge the industry." Why is this important for composites? "Because composites are not very accurate," Helgosson replies. "For example, the thickness of an aircraft skin can vary by 8-10%, but tolerance for fitting parts to it is only 0.1 mm. is is a big problem." Until now, the solution has been more shimming vs. all-metal aircraft assembly. But according to Helgosson, the big goal for all four major OEM partners in LOCOMACHS was to reduce shimming costs by 50%. Working with Composites One is a unique partnership with our PEOPLE . From regional customer service reps and technical sales teams, to local support teams at over 35 distribution centers in the U.S. and throughout Canada, we'll make sure you find what you need, and receive it when you need it. As your partner, we'll give you access to emerging market expertise and process application know-how, and do what it takes to help grow your business. We'll also provide you with the unmatched service and support you should expect from North America's leading composites distributor. That's the power of Partnership. The Power of One – Composites One. 800.621.8003 | www.compositesone.com | www.b2bcomposites.com People | Product | Process | Performance "At Composites One, we make it our business to know your business." Gary Yoder, Driver, Goshen, IN Visit the all-new compositesone.com.