CUSTOM SYSTEMS ::: 5 AXIS Trim and Drill

Some systems are so demanding in their scope as to require a completely custom design. Completely custom machines are difficult and expensive for most manufacturers to create because of the inefficiency of the design process. Most manufacturers are designed to handle large quantities of similar machines, and custom machines require long lead times and very high costs. Robotic Solutions has a streamlined and efficient design process perfect for one-of-a-kind machines. There are no bounds on machine shape, style, or function. This makes our custom machines perfectly suited to their task.

This 5 axis router needed to drill and rout in a composite fuselage section. The work envelope was a cylinder 20’ diameter, 40’ length. This machine design is ideal because it allows the part to be side loaded with access on all sides but the cutting side. The machine has a 12’ reach, allowing it to cut half of the part at a time, requiring the part to be rotated only once. The operator platform is up near the part for easy viewing, but the operator also has access to numerous cameras mounted around the machine for command viewing of the part and the environment. The operator has multiple monitors and can view many cameras at once with ease, or can focus on one view with the 36” HD LCD monitor for an unparalleled view of the work.

With a 40’ traverse, high speed was necessary to keep cycle times down. Heavy duty direct drive linear motors keep the machine nimble despite its size, and ensure the design will never lose its accuracy, thus ensuring the investment will last through the end of any program.

Another issue with this machine was the possibility of uneven or inaccurate surfaces due to the fiber placement process. A surface sensing device was needed to compensate in real time for any thickness imperfections to keep the depth of cut consistent. Keeping the spindle rigid, a floating end effecter with high resolution feedback and chip collection capabilities was devised to feed real time positions into the control to adjust the depth of cut according to the actual surface depth. This end effecter solved the problem of dust and cut depth accuracy.

The parts that are cut on this machine are very important, and tracking each one is important to this customer, as well as their customer. The cameras can be accessed online to demonstrate the process, track production, or troubleshoot the process. At any time, anyone associated with the system can check its status from anywhere via the internet. This feature, like many others, is integrated directly into the control and has direct access to real time system information. The open architecture of the software makes adding features after installation easy as well.