Robotics Technologies and Composites

Robot Technologies and Composites With Industry 4.0, robot technologies began to be incorporated into industry. Today, with ever-developing technology, the rules of production are being rewritten. In this new era, the technologies that are most used and provide the greatest benefit in production are automation and robot technologies. So much so that one of the keys to having a strong industry is seen as incorporating automation and robot technologies into production in proportion to developing technology. Composite materials are characterized by scientists as groundbreaking materials used in important sectors such as aerospace, defense, energy, and space. Composite materials, created by bringing together multiple different components, not only are used in many sectors but also can provide many superior properties. Here, adapting production processes to developing technologies is important for the flawlessness of these materials.

Benefits of Robot Technologies

Looking at production before Industry 4.0, we can see that it was based entirely on human labor, intelligence, and skill. In this production system, everything was recorded by humans and monitored by humans. This particularly led to errors in mass production. Today, thanks to automation systems and robot technologies, there is less need for human labor and more errorless and faster mass production has begun. The important point here is that since machines operate with a specific system, they can produce mass quantities in exactly the same way from the desired material. At the same time, it has been observed that thanks to supervisory artificial intelligence, tests performed on materials can be applied more accurately, and thus more flawless materials can be achieved. Looking at the benefits robots provide in production in general, we can see that they increase efficiency and raise production quality. Robots can perform every task at the same speed and quality without tiring or losing focus. At the same time, quality can be increased in produced materials through the use of equipment for quality control. Another contribution of robot technologies is to worker health and safety. Robots can be designed to work easily even in harsh conditions that would adversely affect worker health. This will result in workers working less in these conditions, thereby reducing the risk of workplace accidents and risks to human health. Similarly, robot technologies ensure standardization in production. This will make it much easier to perform cost analyses since production will maintain a fixed quantity of products per unit time. Thus, spent time and energy consumption can be calculated more accurately, and through more accurate cost analysis, better pricing can be achieved. Like in many areas, robot technologies are being utilized in composite production as well. It is thought that with developing technology, robot technologies will be increasingly used in materials to be produced for sectors such as automotive and aviation that expect flawless production. At the same time, composite materials are also being utilized in robot production. Especially when manufacturing robot arms, composites are preferred for the superior properties they offer. Looking at robot technologies, we can see that composite material is frequently used in robot technologies and these technologies are being utilized in composite production. In particular, robotic manufacturing technologies are being used in manufacturing methods for polymeric composites. OFS machines developed with robot technology have begun to be used in the manufacturing of large parts to be used in defense, aerospace, and space applications. These machines stand out for their ability to move in many different directions and perform layup processes.

Focusing on Machining and Assembly of Composite Structures

Most companies aim to contribute to the production of composite materials with the robot technologies they develop. For example, Fraunhofer IFAM recently announced that they have advanced their automation and robotics development targets for large composite structures. With these targets in broad outline, they are focusing on developing automatic or semi-automatic manufacturing solutions for machining and assembly of large, lightweight composite structures. With the Commands 2 project, Fraunhofer IFAM, together with its partners, developed mobile, lightweight robot systems for efficient and sustainable assembly of aircraft components.

Robotic Arm Developed for Work on Aircraft Wings

Loop Technology announced the development of Bravura, a robotic arm that provides highly precise automation, including sealing and inspection in aircraft wings and other enclosed spaces. The technology was produced as a result of a four-year research project conducted by Spirit AeroSystems and the Aerospace Technology Institute, which ended in September 2022. According to Loop Technology, assembly in enclosed spaces such as wing boxes was quite difficult. The newly developed robotic arm will provide ease in this manually performed work. Robotic machining is typically suitable for softer materials such as wood, engineering foam, or sand casting molds. However, the latest technology in robot technology was used and it is suitable for use with harder materials such as cured carbon fiber.

Robotized System Makes Upper Molding Mobile and Flexible

Anybrid's ROBIN demonstrates online/offline functionalization of profiles, 3D-printed panels, and bio-based materials for more efficient, sustainable composite parts. Anybrid's new automated systems, such as robotic injection molding (ROBIN), offer a way to functionalize composite components by eliminating adhesion and facilitating lightweight assemblies. Michael Stegelmann, managing partner at Anybrid, stated that they developed this robotized injection molding machine in 2019 to produce hybrid components.

Disadvantages

When examining what the disadvantages of robot technologies might be, capital cost is the first thing we encounter. To incorporate robot technologies into production processes, manufacturers need to allocate a certain amount of capital and make investments in this area. However, even though this is seen as a disadvantage, it can also provide positive investment returns. Another disadvantage is that the initial installation of robots requires a great deal of training and expertise. Automation companies mostly provide support in matters such as robot technology installation. Engineers can also be trained in these areas. However, support from experienced automation companies is still required for the integration of robot systems. Another disadvantage is that some of the tasks robots can perform have certain limitations. It may not be efficiently used in every desired area. For this reason, it is necessary to clearly determine the area where it will be used and to carefully measure how well the robot can work in integration with the systems there. Despite its disadvantages, it is expected that robots will be used more in the industry in the near future. It is thought that utilizing robot technologies with lower error rates, especially when working with materials like composites that expect flawless parts, will develop the composite industry in a positive direction. Compiled by: Nilsu Kotil Source