Posted to News on 20th Jun 2007, 16:45
KUKA robot used to laser weld titanium components
CAV Aerospace has increased productivity by installing a KUKA robotic laser welding cell to weld titanium panels used on the leading edges of light aircraft wings for dispensing glycol-based fluid for ice protection.
A KUKA robotic laser welding cell has transformed the production of safety-critical light aircraft components made by CAV Aerospace, a market leader in ice protection systems.
The high-speed performance and flexibility of the equipment has so impressed the company that it has ordered a second cell for producing other aircraft products.
Meanwhile, the first cell is already helping to boost productivity by rapidly laser welding titanium panels used on the leading edges of light aircraft wings for dispensing glycol-based fluid for ice protection. CAV Aerospace is now able to weld a single panel in just a fraction of the time compared to its previous labour-intensive method, which involved fastening up to 300 rivets by hand.
Safe Robot functionality
Components are manually loaded along a KUKA-designed track into the fully-enclosed cell that features a KUKA KR150 robot equipped with a Trumpf YAG pulsed laser. KUKA has not only incorporated a RFID system to simplify and speed-up changeovers between different component sizes, but also added working-range monitoring with its Safe Robot functionality.
Automating part of the production process for its TKS brand of ice protection systems was a crucial factor for boosting output following a substantial increase in new business, explains Paul Bradbury, CAV Aerospace's engineering manager: "It was also important to help maintain a competitive advantage rather than run the risk of losing out to the competition. KUKA was chosen for the project because of its expertise in robotic welding applications."
Since the cell had been installed, significant improvements in efficiency and productivity are already evident and these are expected to rise further when full capacity was achieved.
Gary Taylor, aerospace manager at KUKA Automation + Robotics, comments: "This installation is an excellent example of how robots can efficiently and reliably automate traditional, labour-intensive methods in the aerospace industry at a time when component makers are under pressure to find alternative solutions to stay one step ahead of competitors.
"Robots and automated production systems are becoming increasingly vital to the aircraft industry, as manufacturers and suppliers strive to deliver the volumes required to satisfy global demand."
