automation solutions for complex composites · 2020-05-12 · key for automated fiber placement on...

May 2020 1milestones in composites

milestones in composites

May 2020 milestones in composites

Automation solutions for complex compositesSAMBA & ARTIST STUDIO | Fiber Patch Placement by Cevotec



Long production cycles

No effective quality control

High scrap rates >30%

High cost

Need for automation solutions?

Complex composites still manufactured by hand!



Fiber Patch Placement Additive 3D fiber lay-up platform for complex composites

www.cevotec.com/en/fpp-technology/

3D fiber lay-up automation platform

SAMBA Series

CAE software for design & production

ARTIST STUDIO

Benefits

20% - 60% cost & time savings

Multi-material layup capability

Digitized, automated process chain

100% in-process raw material control

http://cevotec.com/en/fpp-technology/



Complex

geometries

Tailored

reinforcements

Automotive

Medical

Additional

Focus industries Primary applications

Multi-material

componentsAerospace

Replacing manual lay-up in a broad range of applications.

Focus industries & applications



Fiber Patch Placement (FPP) – flexible lay-up technology for complex fiber composites

The Cevotec process

Enabling a fully automated, quality-controlled 3D lay-up for complex composites


1. Feed fiber tape

2. Cut tape into patches

3. Inspect quality

4. Pick-up, check position

5. Place fiber patch




The Cevotec patch gripper: adapting to complexityUp to 300 mm x 400 mm. Suitable for multi-material placement. Equipped with compaction-force sensor.

Key for automated fiber placement on complex surfaces

Controlled fiber deposition

on concave & convex surfaces

Placement onto a honeycomb core

adhesives, glass, carbon, etc.

Examples of sandwich core components in aerospace

Size tailored to application

up to 300 mm x 400 mm

Force-torque sensor for

compaction monitoring available



Productivity of FPP lay-up systemsEffective lay-up rates result from process parameters and can be customized to applications.

ሶ𝑚 =𝑝𝑎𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ ∗ 𝑝𝑎𝑡𝑐ℎ 𝑤𝑖𝑑𝑡ℎ ∗ 𝑎𝑟𝑒𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 ∗ 𝑛𝑜. 𝑟𝑜𝑏𝑜𝑡𝑠

𝑝𝑎𝑡𝑐ℎ 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒

∙ SAMBA Series systems are equipped with placement robots

and mold manipulators that best fit your application

∙ For high throughput requirements, two or more placement

robots can be fed by one feeding unit.

∙ The graph illustrates achievable lay-up rates based on

different SAMBA Series configurations.

Customized to individual applications, FPP systems achieve high lay-up rates

Typical rate of hand lay-up: < 3 kg/h

0 25 600 1200

Lay-up rate [kg/h]

Patch size [cm2]

30

25

20

15

10

5

0

500 gsm @6 s/patch

300 gsm @6 s/patch

100 gsm @1,5 s/patch

200 gsm @1,5 s/patch

500 gsm @7 s/patch

300 gsm @7 s/patch

equals DIN A4 size equals DIN A3 size

Lay-up rates of SAMBA systems



Significantly shortened process for complex composite lay-upsWorking with standardized fiber tape cuts process time & cost – no nesting, cutting and kitting required

Process time & cost reductions of 20% - 60% with Fiber Patch Placement

Development phase Recurring production

CAD

part design

Laminate

design

Robot

programming

Fully automated

3D lay-up on mold

CAD

part design

Laminate

design

Nesting

software

Cutting

software

Laser projection

software

Cutting

on CNC table

Kitting /

pre-stacking

Hand lay-up on

mold

Conventional process

Fiber Patch Placement

Artist Studio SAMBA Series



Additive 3D fiber lay-up systems for multiple fiber materials. Sample configurations for different application scenarios.

SAMBA Series

SAMBA Pro

∙ Fast scara robot

∙ Robot-based

tool manipulator

∙ Ideal for batch

production

SAMBA Scale

∙ One material feed with large tape

∙ High throughput rates

∙ Multiple placement robots

∙ Ideal for volume production

SAMBA Multi

∙ Up to 4 tapes in parallel feed

∙ Suitable for carbon, glass, adhesives, etc.

∙ Long-reach robot for large tools

∙ Ideal for multi-material aerostructures

SAMBA Step

∙ Tray-based material feed

∙ 6-axis placement robot

∙ Maximum material flexibility

∙ Ideal for prototyping / R&D

All systems available in dry fiber and thermoset-prepreg configurations



Tailored configurations – variety of placement robots – robot-based tool manipulators

Module 1: Feeding & cutting Module 3: Tool holders & manipulators

Module 2: Placement robots

SAMBA Pro

SAMBA ScaleSAMBA Multi

SAMBA Step

Modular system architecture for maximum flexibility. Systems adaptable to specific applications.

SAMBA Series modules



Continuous process & quality control with a multitude of integrated sensor for key process parameters

Superior process control with Fiber Patch Placement

Controlled deposition process

· Temperature

· Pressure

· Compaction time

· Contact time from pick-up to

deposition

Vision control patch position

· Position

· Orientation

· Self-correcting process for

precise placement

Vision control patch

· Length & width

· Cutting edge

· Waviness

· Quality check for

non-conforming patches

Real-time production data analysis

and comparison with a database of

previously processed patches

Controlled tape feeding

· Temperature for material storage

· Controlled tape pull-off

· Automatic tape positioning to

centricity

Station for in-process gripper exchange

· Automated contamination detection

Global parameters:

· Temperature & humidity

in placement cell

· Frequency of patch

deposition

· Cycle time

· Mass throughput

Objective: Replace individual unit tests by continuous process monitoring

Interfaces for integration

into existing process

control landscapes



Comprehensive CAE software platform for Fiber Patch PlacementEnabling a continuous virtual process chain for patch technology

CAD – PATCH ARTIST

CAM – MOTION ARTIST

ARTIST STUDIO PLUG-IN

for commercial FE software

Generate a patch-based laminate with

optimized patch overlaps

Generate machine data through

offline robot programming

Simulate mechanical

behaviour

(stiffness, strength)

Digital development suite cuts design-to-prototype time from days to hours



SAMBA SeriesFiber lay-up automation platform

The Cevotec portfolio

Your partner in patch-based production equipment & software.

cevoLab – the FPP Competence CenterApplication development, prototyping, customization

ARTIST STUDIOCAE software platform

Automation solutions for complex fiber lay-up

· Flexible 3D fiber lay-up platforms

· Configurations tailored to applications

· Self-corrective process control

· 20% - 60% cost & time reduction

· CAD-CAM for patch technology

· Incl. plug-in for FE software

· Perfectly matches SAMBA systems

· Application development, prototyping & low-volume production

· CAE analysis & FEM-based optimization

· Process and SAMBA system customizations

· Tailored patch grippers

in cooperation with




We enable manufacturers to produce complex composites in high volume and superior quality.

For a lighter, more sustainable future.

Get started with

Fiber Patch Placement

+49 89 2314 1650 [email protected] www.cevotec.com

- Step 1: ROI & suitability assessment -

Includes manufacturability assessment, unit cost & time

analysis, benefits & ROI estimation. This service is

complimentary for you.

→ How much does your application benefit from FPP?

- Step 2: Joint application development -

Includes virtual studies, application and demonstrator

development, equipment customization, and more.

→ How do you best develop & test your FPP application?

- Step 3: Customized lay-up equipment -

Includes SAMBA lay-up systems, ARTIST STUDIO software,

customized patch grippers, quality control systems, and more.

→ Which system configuration is best for your application?

How to get started with FPP

mailto:[email protected]?subject=Getting%20started%20with%20Fiber%20Patch%20Placement!

https://www.cevotec.com/en



References & partners (selection)

International sales partners

North America:

Composite Automation

http://www.compositeautomation.com

John Melilli: [email protected]

Japan & Thailand:

Fuji Industries Co. Ltd.

http://www.ficjp.com/en/

Noriyuki Ueno: [email protected]

Strategic partners

Strong partners share our vision, support us and

work jointly with us towards a better future!

References

Premier OEM, manufacturers and institutes develop innovative automation solutions with us. Among them:

http://www.compositeautomation.com/

mailto:[email protected]

http://www.ficjp.com/en/

mailto:[email protected]



Exclusive preview of SAMBA preforming demoMay 6, 2017

From the press (selection)

Cevotec celebrates successful market launch at JEC World 2017May 28, 2017

Cevotec presenta l’imbuto di finestra al progetto Fiber Patch Placement del Paris Aviation ShowJuly 05, 2017

Fiber Patch Placement machine, softwareApril 19, 2017

Cevotec Samba: software en robotcel voor 3D composietdelenMay 13, 2017

Complete press review: http://cevotec.com/en/from-the-press/

Mit Fiber Patch Placement zum komplexen 3D-BauteilSeptember 06, 2017

Direct 3D-preforming with Fiber Patch PlacementMay 10, 2018 (p. 14-15)

Fiber Patch Placement soll Automotive-Leichtbau revolutionierenSeptember 11, 2018

Carbon-Patches verstärken die KarosserieSeptember 17, 2018

Trip the light fantastic!January 17, 2019

Cevotec scales up FPP technology for large aerostructuresJanuary 17, 2020

New composites technologies will help meet the growing demand for civil aircraftMay 03, 2019

Mobilität der Zukunft mit Fiber Patch PlacementFebruary 14, 2019

Industry 4.0 automation for building complex compositesAugust 23, 2019

Fiber Patch Placement wins JEC Innovation Award in SeoulDecember 06, 2018

http://www.compositesworld.com/blog/post/exclusive-preview-of-samba-preforming-demo-

http://www.insidecomposites.com/automation/cevotec-celebrates-successful-market-launch-at-jec-world-2017/

http://newsimpresa.pentaconsulting.it/cevotec-presenta-limbuto-finestra-al-progetto-fiber-patch-placement/

http://www.todaysmotorvehicles.com/product/cevotec-fiber-patch-placement-system-041917/

http://www.made-in-europe.nu/2017/03/cevotec-samba-software-en-robotcel-voor-3d-composietdelen/

http://cevotec.com/en/from-the-press/

https://www.k-zeitung.de/mit-fiber-patch-placement-zum-komplexen-3d-bauteil/150/4794/104232/

https://www.compositesolutions.it/en/archives/archive-2018/issue-22018/

https://www.automobil-produktion.de/technik-produktion/produktionstechnik/fiber-patch-placement-soll-automotive-leichtbau-revolutionieren-253.html

https://industrieanzeiger.industrie.de/technik/carbon-patches-verstaerken-die-karosserie/

https://www.aero-mag.com/trip-the-light-fantastic/

https://www.compositesworld.com/news/cevotec-scales-up-fiber-patch-placement-technology-for-large-aerostructures

http://compositesmanufacturingmagazine.com/2019/05/aircraft-manufacturers-looking-for-speed/

https://www.k-zeitung.de/mobilitaet-der-zukunft-mit-fiber-patch-placement/

http://www.jeccomposites.com/knowledge/international-composites-news/industry-40-automation-building-complex-composites?utm_source=SalesForceMarketingCloud&utm_medium=email&utm_campaign=JEC+Composites+Market+News+N.+810

https://www.compositesworld.com/news/fiber-patch-placement-wins-jec-innovation-award-in-seoul

Product details

SAMBA Series & ARTIST STUDIO



Additive 3D fiber lay-up systems for multiple fiber materials. Sample configurations for different application scenarios.

SAMBA Series

SAMBA Pro

∙ Fast scara robot

∙ Robot-based

tool manipulator

∙ Ideal for batch

production

SAMBA Scale

∙ One material feed with large tape

∙ High throughput rates

∙ Multiple placement robots

∙ Ideal for volume production

SAMBA Multi

∙ Up to 4 tapes in parallel feed

∙ Suitable for carbon, glass, adhesives, etc.

∙ Long-reach robot for large tools

∙ Ideal for multi-material aerostructures

SAMBA Step

∙ Tray-based material feed

∙ 6-axis placement robot

∙ Maximum material flexibility

∙ Ideal for prototyping / R&D

All systems available in dry fiber and thermoset-prepreg configurations



Tailored configurations – variety of placement robots – robot-based tool manipulators

Module 1: Feeding & cutting Module 3: Tool holders & manipulators

Module 2: Placement robots

SAMBA Pro

SAMBA ScaleSAMBA Multi

SAMBA Step

Modular system architecture for maximum flexibility. Systems adaptable to specific applications.

SAMBA Series modules



Modules for tape feeding and cutting differ according materials processed. Up to 4 parallel tapes with different materials in feeding unit possible. Ultrasonic or laser cutting. Customizations upon request..

Module 1: Feeding & cutting units

SAMBA Scale· Tape width: > 50 mm

· Areal weight: > 250 gsm

· One sensor-controlled tape feeder

· Ultrasonic or laser cutting

· Visual quality inspection

SAMBA Step· Manual placement of

pre-cut patches on trays

· Maximum material flexibility

· Patch size depend only on

gripper size

· Visual position recognition


SAMBA Multi· Tape width: to specification

· Areal weight: to specification

· Automated feeder supplying

4 tapes in parallel



SAMBA Pro· Tape width: 12.5 – 50 mm

· Areal weight: < 300 gsm

· One sensor-controlled

tape feeder



Feeding and cutting units are adapted to a range of suitable materials according to applications



Placement modules individually designed to fit specific applications. Standard robots: Stäubli, Kuka. Additional brands on request. Linear axis for extended reach optional.

Module 2: Placement units

Scara fast-picker· Fast-picker for shortest

placement cycle time

· Positioning control unit for precise

patch deposition

· Integrated heating for prepreg

processing

· Good choice for medium to smaller

sized parts with high to medium

complexity

· Illustration: SAMBA Pro

Linear axis large· Linear axis for feeding unit in combination with 6-axis robot

· Size of robot & gripper specific to application

· Positioning control unit for precise patch deposition

· Integrated heating for prepreg processing

· Best choice for large parts with > 2m in width

· Illustration: SAMBA Multi

Linear axis small· Linear axis for placement robot only

· Size of robot & gripper specific to application

· Positioning control unit for precise patch deposition

· Integrated heating for prepreg processing

· Best choice for larger parts and multiple robots

· Illustration: SAMBA Scale

6-axis robot· Most flexible robot choice

· Size adapted to application

Positioning control unit for

precise patch deposition

· Integrated heating for prepreg

processing

· Several robots per feeding unit

possible

· Illustration: SAMBA Step

Placement units can be flexibility combined with feeding and cutting units



Tool holders and manipulators are specific to each application and can be exchanged easily on each system. Options with standardized quick-mount tooling systems available for flexible production settings.

Module 3: Tool holders and manipulators

Tool holder (large)· Individual tool holder

· Adapted to component

· Degrees of freedom

according to specification

· Typically combined with 6-

axis placement robot on

linear axis

· Illustration: SAMBA Multi

6-axis robot· Flexible tool holder for

medium to smaller parts

· Can be combined with any

placement robot

· Illustration: SAMBA Pro

Tool rotator· Rotating tool holder

· Adapted to component

· Degrees of freedom according to

specification

· Typically combined with 6-axis

placement robot

· Illustration: SAMBA Scale

Tool manipulators specific to components – quick-mount tooling options for flexible production available

Tool table· Fixed tool holder

· Size adapted to component

· Typically combined with 6-axis

placement robot

· Illustration: SAMBA Step

Linear table tool· Movable table for 2D patch

placement

· Can be combined with

6-axis robot for automation

· Size adapted to specification

Other options

upon request



Comprehensive CAE software platform for Fiber Patch PlacementEnabling a continuous virtual process chain for patch technology

CAD – PATCH ARTIST

CAM – MOTION ARTIST

ARTIST STUDIO PLUG-IN

for commercial FE software

Generate a patch-based laminate with

optimized patch overlaps

Generate machine data through

offline robot programming

Simulate mechanical

behaviour

(stiffness, strength)

Digital development suite cuts design-to-prototype time from days to hours



ARTIST STUDIOCAD-CAM software for patch technology

Export of patch laminate for FEM simulation



Plug-in for commercial FE softwareEnabling FE analysis on sublayer & patch level, accurately predicting mechanical propertiesPlug-in for HyperMesh

Enabling FE analysis on patch- & sublayer level

Beyond application:

The theory, principles and science behind Fiber Patch Placement technology



Natural Fibrous Structures

Human boneTree trunk

Technical Structures

Airport hall Topology

optimized chassis

Curvilinear carbon

fiber orientation

Fibers follow curved paths

→ Transferring the principle to lightweight construction

→ New curvilinear textile technologies

→ Fiber Patch Placement

Direct fiber patch placement on

3D geometry or along 3D load paths

Motivation for Fiber Patch Placement technology

Bionics lightweight design

Leaf



Fact

Multiaxial non-crimp fabrics such

as quasi-isotropic lay-ups cannot

exploit the full potential of the

material.

Example

Only 15° deviation to a tension-

based load path leads to an

extremely reduced strength

(>80%)

Patch lay-up supports

optimal lightweight design

Average fiber-to-load deviation is significantly reduced with Fiber Patch Placement

Massive drop in strength of classical laminates



2.5x stiffness increase with load-optimized patch laminate

High performance lightweight design with Fiber Patch Placement

Source: Cevotec and Technische Universität München

5,23

13,3

5,31

12,35

5,05

13,6

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

quasi isotropic lay-up FPP lay-up

Mass-specific stiffness [kN/(mm∙g)]

+150%

simulation specimen 1 specimen 2 simulation specimen 1 specimen 2150 mm

21

0 m

m

F F

F F

Optimized patch lay-upQuasi-isotropic lay-up



Source: O. Meyer, Short fibre preform technology for load path aligned manufacturing of fibre reinforced plastic components, Doctoral thesis, University of Stuttgart, 2008

Mass-specific

maximum strengthF

F

F

F

+120%

Demonstration at an open hole specimen

2.2x strength increase through curvilinear fiber orientation

Biaxial non-crimp fabrics Load path oriented fibers (patch basis)



MT

MT

Quasi-isotropic lay-up Lay-up with patch layers

4 unidirectional layers

with 2 patch layers8 unidirectional layers

45°

-45°

90°

0°

0°

90°

-45°

45°

MT

MT

FPP

45°

-45°

-45°

45°

FPP

8 unidirectional layers

20% weight reduction

4 unidirectional layers + 2 patch layers

Load-path-oriented reinforcements reduce material, weight and cost

20% weight decrease with patch reinforcements



Discontinuous /

patch process

The patch process enables high-complexity parts with cost-efficiency and volume capabilities.

Key enabler: the Cevotec patch process

Continuous fiber process

effort / cost

partcomplexity

Processing multiple materials in parallel

100% in-process raw material control

Patch technology enables …

Automated complex direct 3D lay-up

Locally load-optimized lay-up design

Continuous fiber

complexity barrier

Cevotec GmbH

Biberger Str. 93

82008 Unterhaching

Phone +49 89 2314 165 0

Fax +49 89 2314 165 99

[email protected]

www.cevotec.com


automation solutions for complex composites · 2020-05-12 · key for automated fiber placement on...

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