QMI Solutions is constantly seeking innovation in process technology to meet the needs of Queensland industry. Below are some of the new technologies that QMI Solutions has investigated.
Automated Tape Laying and Automated Fibre Placement
Automated Tape Laying (ATL) and Automated Fibre Placement (AFP) are two complementary processes for the manufacture of fibre composite components. In both cases, raw material on rolls is automatically placed across the surface of a tool to produce the desired shape. This replaces the labour intensive hand lay-up process. Generally, tape and fibre laying systems consist of a robot or gantry based guidance system, coupled to a placement head which lays down the raw material in the desired position. The advantages of the system are the level of automation and the consistency and repeatability of the products.
In the ATL process, material can be applied in tape form up to 12 inches wide and is generally of a graphite epoxy pre-preg material. The head removes the backing paper, applies pressure to ensure good adhesion and compaction cuts the tape strips to the required length. The head is mounted on a 4 or 5-axis gantry or robot, depending on the complexity of the part being manufactured. The limitations associated with the tape material itself means that the ATL process is used for flat, near-flat or contoured parts with large radii.
Sponge Blasting
The current environmental requirements facing some companies impacts particularly on industries where residential developments are encroaching upon land previously devoted to industrial and manufacturing operations. The increasingly stringent environmental requirements faced by these companies causes them to seek alternative technologies for processes such as hull cleaning and paint stripping.
One such opportunity lies in the adoption of Sponge Blasting, a process which replaced traditional sand or garnet based blasting media with small pieces of spongy material impregnated with an abrasive such as Aluminium Oxide. As a result up to 90% of airborne dust is reduced, permitting the cleaning process to run in conjunction with other maintenance and manufacturing operations. In addition, the good visibility of the work piece permits a greater level of precision in the blasting process, leading to faster and more consistent surface finishing properties.
Hand-held/portable Water Jet Cutting
The marine industry is constantly seeking new innovations, particularly in equipment that is used to maintain and repair large hulls. These systems must be transportable or portable as the work piece cannot be moved. One such process is Water Jet Cutting, commonly used to remove damaged or corroded sections of metallic or composite structures. A request for information on the availability of portable Water Jet Cutters was received. Whilst no truly "hand-held" systems were located, due to health and safety implications, a semi-portable system was identified.
The Jet Edge Versacutter is a motion controlled, portable abrasive-jet cutting and beveling system. The system is used in a variety of cutting applications including pipelines, steel reinforced concrete, reactor vessels and fabricated metal structures. The Versacutter cuts without flames and does not generate heat. This makes it possible for operators to cut in areas where flames are restricted and eliminates heat-affected zones. It also permits straight and beveled cuts to be set-up in a variety of materials. Curved surfaces can also be cut using the flexible track.
Multi-point Forming
Multi-point Forming (MPF) is a technique for the manufacture of 3D sheet metal parts that cannot be processed by conventional means. This technology is being investigated at the Roll Forging Research Institute at Jiling University in China, primarily for structural applications. It is also under development as a fixtureless manufacturing process for aircraft panels, in conjunction with the Manufacturing Engineering Centre at Cardiff University in the UK.
The MPF process utilises multiple punches arranged on a grid to form the required shape. These adjustable punch matrices replace the traditional solid tooling associated with sheet metal forming. The MPF actuators are also reconfigurable, which results in the ability to manufacture many different shapes using the same actuator bed, based on the digital design of the part. This reduces the cost when compared to conventional tooling.
Hybrid Parallel Kinematic Robots
The Hybrid Parallel Kinematic Robot is a new kind of architecture for robotics which gives advantages and disadvantages over the conventional serial structure. This leads to new applications for which robots were traditionally unsuitable, particularly in aerospace, food and automotive applications.
Parallel Kinematic Machines (PKM) utilise six legs in parallel rather than in a serial configuration. The most well known example of a PKM is the flight simulator, which exhibits very rapid motion and changes of direction but has a limited work envelope.
To combine the best features of both robots and PKMs, the Hybrid Parallel Kinematic Robot has been developed. The most widely adopted system to date is the Tricept, originally developed by Neos Robotics. This is now available in a third generation version as the Exechon. These new architectures combine features of both full PKMs and serial robots. In common with PKMs they are stiff, accurate and can apply large forces. However, they also share a number of disadvantages. Just like PKMs they have a complex workspace and require large amounts of computing power to calculate trajectories, and just like serial robots, small errors due to heat and load are amplified along the kinematic chain.
A number of industries have embraced hybrid parallel kinematic machines including the food industry and automotive industry.
For more information or advice, please contact:
Consultant: Sara Eastwood
Phone: +61 7 3364 0700
Email: info@qmisolutions.com.au