CompositesWorld

NOV 2017

CompositesWorld

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NOVEMBER 2017 36 CompositesWorld FEATURE / Reconfigurable Tooling Roundup e tooling Prodtex demonstrated with its LOCOMACHS partners achieved the proj- ect's goal. "e objective was to enable this novel best-fit assembly method," Helgosson explains. "We did this by integrating an automated flexible assembly fixture, which demonstrated two major accomplishments." First, two synchronized Hexapods were used to position the front spar to the upper cover, hold it in place and maintain tolerance while withstanding 500N drilling forces during cover-to-spar assembly. Second, a 6DoF force feedback sensor, used with a third hexapod robot, managed rib placement as they were automatically positioned to best-fit locations in the wingbox. "We were able to manage the thickness variations of the parts without the need for shimming," Helgosson adds. One of the most significant benefits of reconfigurable tooling is that it limits risks. Prodtex reconfigurable tooling is designed using Dassault Systèmes (Vélizy-Villacoublay, France) CATIA 3D CAD software and DELMIA V5 manufacturing simulation software. e latter is used to simulate robots and automation. BoxJoint, ShimBox, Hexapod/Flexpod and TFS Units are all integrated into CATIA and DELMIA. When a fixture is designed and constructed, pickups are mounted using a laser tracker to measure their locations and check against the digital mockup — the CATIA model translated into metrology software. "Automation demands precise position vectors for the robots to be able to interface with the parts," Helgosson explains. "If the assembly design changes, or if the tooling has to be modified with another pickup or tolerance change, you just adapt the CATIA model, add or subtract parts and recalibrate," says Helgosson. "It's almost concurrent engineering, which is invalu- able in aerospace assembly, because it is so complex, with so many parts and processes dependent on each other." Reconfigurables, moving forward Prodtex has supplied a variety of recon- figurable tooling solutions to Airbus (Broughton, UK), Embraer (São José dos Campos, Brazil), Marshall Aerospace (Cambridge, UK), Volvo Construction (Arvika, Sweden) and others. When GKN Aerospace (Bristol, UK) wanted an automated process for drilling wing- skins, Prodtex developed test fixtures for GKN and KUKA Systems Aerospace (Le Haillan, France). "e overall project was complex," recalls Helgosson, "because GKN could not interrupt current produc- tion to see if the tools and system would work." us, Prodtex designed and built a fixture for trialing the new process and automated drilling robot. But before this test could be completed, KUKA needed to trial the new drilling end-effector it had developed. "So we built a smaller fixture using our technology," he adds, "which KUKA used before shipping the end- effector to GKN for their test." Another example is an assembly fixture for the cost-effective winglet developed by GKN Aerospace (Isle of Wight, UK) from the STeM program. It features a carbon fiber composite lower skin as well as robotic and lightweight fixing techniques W T F yoming est ixtures INC. • Over 40 types of fixtures in stock, ready to be shipped. • Expert consultation with Dr. Adams • Email or call today to discuss your fixture and custom design needs. Fastener Double Shear Test Fixtures NASM 1312-13 2960 E. Millcreek Canyon Road Salt Lake City, UT 84109 Phone (801) 484.5055 Fax (801) 484.6008 email: wtf@wyomingtestfixtures.com www.wyomingtestfixtures.com Dr. Donald F. Adams President 50 years of Composite Testing Experience WE HAVE A VARIETY OF CUSTOM SHEAR FIXTURES We provide quotes for a variety of grips, fixtures, and jigs. We carry over 40 types of fixtures in stock, available for immediate delivery. Email or call us today. We look forward to hearing from you. Amsler Double Shear Test Fixture ASTM B 769 Fastener Single Shear Test Fixture NASM 1312-20 Custom Pin Single Shear Test Fixture

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