Control of the milling head in a mobile CNC milling unit

09/28/2017

Fiber-reinforced composite materials are increasingly used in the aviation and automotive industries. Due to their robustness and low weight, these are particularly attractive for these industries. When damage occurs, special challenges must be overcome during maintenance and repairs. The damaged area must be removed layer by layer in order to enable the reconstruction of the laminate layer. Here, it is particularly important to avoid split fibers and delaminated layers. To date, these complex repairs were carried out manually. Automated, non-contact surface measurements using modern sensors enables defects to be eliminated within the shortest possible time. For repair work on airplanes, company SAUER GmbH developed the ULTRASONIC mobileBLOCK, which is a mobile 5-axis milling unit.

For defect recognition on components, SAUER relies on optical sensors from Micro-Epsilon. Laser scanners detect the geometry of the defects. As the component can be damaged anywhere, the surface must be measured before the repair process starts. The sensors must measure on different surfaces, which are painted, unpainted or weathered. In order to avoid collisions, the optoNCDT 1302 laser triangulation sensor measures the distance from the surface at a measuring range of 200mm. Subsequently, a scanCONTROL laser scanner measures the surface profile. Next, the program for the repair process is generated based on the acquired 3D data.

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