JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 53

multiple aerospace and CFRP applications. Examples include abrasive
waterjet cutting (RazorJetTM) and
non-destructive ultrasonic inspection
(NSpectTM). In both instances, “process to part” and “part to process”
have been applied and installed.

Abrasive waterjet cutting

RazorJetTM: part to process

of the array and begins its pre-determined path. The system is automated
to the extent that bar code labels are
used to inform the robot and control
systems of the location, part number,
instrument settings and a host of
other information. Since the robot
handles all motion and positioning,
the machine operator merely loads
and unloads the machine. All subsequent evaluation of the scan data is
performed off-line, thus freeing the
machine to continue to scan parts
without delay.

Carbon-fibre-reinforced
plastics

Taking into consideration the
strengths of robotic motion planning, along with the size and shape of
the parts being processed, engineers
can determine the most reliable and
cost-effective manufacturing solution. Genesis Systems Group has
applied this disciplined approach to

More information
Genesis Systems Group (Davenport, Iowa, USA) has been integrating robots into
various manufacturing processes for over 30 years, with over 4,500 systems installed
globally. The company has been at the forefront of robotic processing of CFRP parts,
gaining considerable recognition within the aerospace sector for its unique approach
and depth of experience and technical ability. Genesis AMP (Advanced Materials
Processing) division was formed to respond to the rapidly expanding use of robotics
in the aerospace sector. Genesis AMP has selected KUKA Robotics as its preferred
supplier for highly accurate and robust six-axis robots.

“Process to Part” applications will
continue to have their place in CFRP
fabrication. As manufacturers determine the best method for their own
fabrication needs, “part to process”
applications may give them that advantage they have been looking for. n

No83 August - September 2013 /

More information:
www.genesis-systems.com

Special JEC Americas 2013

When considering the methods to
manufacture carbon-fibre-reinforced
plastics (CFRP) parts, robotic applications have gained considerable
market value in recent years. Robots
offer accuracy, repeatability, robust
design and flexibility. Also, robotic
cells can be configured in multiple
ways. In “part to process”, multiple
operations can be performed in a

single cell. Since the robot carries
the part to stationary or dynamic
processes, multiple stations can
be arranged around the robot. A
non-destructive scanning system
can perform static measurements as
well as dynamic laser measurements
within the same cell. This approach
has multiple advantages, from labour
savings to process SPC data acquisition as well as improved traceability.
Additional processes can be added
given available space and TAKT time.
The decision regarding which is the
most appropriate method is based
upon the size and type of parts being
produced, quantities required, and
flexibility of the process.

Another instance of “part to process”
method is abrasive waterjet cutting.
Flow International is recognized as
the global leader in this technology.
Flow and Genesis have combined
forces to develop a robotic application with abrasive waterjet cutting,
the RazorJetTM. In much the same
manner as NSpectTM, the RazorJetTM
machine is loaded and the robot
retrieves the part from a simple nest.
The gripper or end-of-arm tool holds
the part continuously. RazorJetTM
then begins the process of determining the true position and shape of the
part using a touch routine. Once the
dimensional characterization is complete, the robot manipulates the part
geometry beneath a fixed nozzle. The
nozzle delivers the abrasive ultrahigh pressure waterjet stream while
the robot path plan moves the part
through the abrasive stream. Most of
the external shape of the part can be
trimmed in a single pass. Depending
on the complexity of the part being
processed, re-grips may be required.
This method eliminates traditional
part holding fixtures and adds flexibility in processing parts.

jec composites magazine 53
http://www.genesis-systems.com
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013

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