Page 23 - AAA NOVEMBER - DECEMBER 2017 Online Magazine

COVER STORY

enabled by advanced processes, automation robots in production applications around the device attached to the component with
and digital technologies. Technologies world. suction cups. Specially developed software
developed could include the manufacturing “We’re using robots in a variety of allows the mobile robot to process 1,000
(3D industrial printing) of complex aero- manufacturing processes, drilling and x 1,000 millimeter surfaces and thick FRC
engine components, and advanced robotic fastening probably being two of the prime structures such as wing connection areas.
and automatic solutions. The developed examples,” says Richardson. “But we’re also For this purpose, it scans the damage,
technologies will eventually be used on-site using robotics for painting and coating identifies the surface and calculates both the
at Rolls-Royce and SAESL’s facilities for applications, for inspection processes, and form of the scarf joint and the milling path
improved productivity, costs savings and for material handling.” before cutting out the damaged material.
business competitiveness. Afterwards, the repair layers are cut to size
Rapid Repairs with Robots and inserted into the 3D scarfing surface
Relying on Robots MRO providers such as Lufthansa Technik created by the robot. The newly inserted part
Leading aerospace suppliers are also relying (LHT) will soon introduce to the aviation is then manually glued to the fuselage and
on robots for their enhanced capabilities industry a highly flexible repair procedure cured. “Mechanical trials during the project
and tried-and-true flexibility. “There’s for structures made of fiber-reinforced proved that the procedure not only enables
been an evolution of how robots are used composites (FRCs). LHT has developed a reproducible repairs of damages but also
in the aerospace industry,” says Curtis stationary scarf joining robot to enable increases bonding strength. This is a major
Richardson, Associate Technical Fellow a continuous process chain for rapid, step toward carrying out adhesive-based
at Spirit AeroSystems, headquartered in automated and reproducible repairs of FRC repairs on critical structures made of fiber-
Wichita, Kansas. “The robots that were in materials. The fuselage and wing structures reinforced composites. With the help of the
our plants 15 or so years ago were targeted of modern widebody aircraft consist largely new robot, mobile service teams are able
at non-precision applications. Since then, of high-performance FRCs. For a long time, – now even on wing – to diagnose and repair
because the capability of industrial robots determining and repairing damage to the large areas of damage on the wings and
has improved, we’ve been able to use them aircraft’s skin sections required a great deal fuselage,” says Dr. Schmutzler.
for many other processes.” of effort, whether the work was carried The preparations for the introduction of
With facilities across the U.S., Europe out in the field or in a workshop. “That a fully industrialized system are currently in
and Southeast Asia, Spirit AeroSystems has changed…and the follow-up project, full swing at Lufthansa Technik. The company
manufactures aero structures for many Composite Adaptable Inspection and Repair” has also filed two patent applications for the
of the world’s major aerospace OEMs, (CAIRE), succeeded in further enhancing the new scarf joining robot. The first is for the
including Boeing, Airbus, Bombardier, Rolls- technology of the stationary scarf joining positioning mechanism that enables a single
Royce, Mitsubishi, and Bell Helicopter. robot to allow for mobile repairs,” says employee to flexibly and precisely position
Core components include fuselages, large project manager Dr. Henrik Schmutzler. the scarf joining robot anywhere on the
wing structures, nacelles, pylons, fan cowls, The mobile robot is even able to aircraft – whether from the side, from above
thrust reversers, and systems integration. recognize free-form 3D surfaces. To make with an overhead crane or even upside down
Spirit AeroSystems says it has more than 40 a scarf joint, the robot is placed on a fixing with the help of hoisting gear. The second

oPPosite PAge: Leading
aerospace suppliers are now
relying on robots for their enhanced
capabilities and tried-and-true
flexibility
LeFt: Lufthansa Technik’s
Composite Adaptable Inspection
and Repair (CAIRE), has succeeded
in further enhancing the technology
of the stationary scarf joining robot
to allow for mobile repairs
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