JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 64

insert

Automated placement of inserts
in composite sandwich panels

By

Dipl.-Ing. Stefan Kögl
Senior Manager Projects
RUAG Schweiz AG, RUAG Space
Business Unit Structures
Prof. Dr. Hans-Peter Gröbelbauer
Team Leader Product Development
University of Applied Sciences
and Arts Northwestern Switzerland
School of Engineering
Institute of Product and Production
Engineering (IPPE)

RUAG Space, a leading European supplier of space products, has a
revolutionary new insert and process (patent pending) that automates the process for placing inserts in composite sandwich panels
for satellites. This significantly cuts down on production time and
cost, as well as panel weight.

Innovation

R

UAG Space develops a wide spectrum of space products, including
satellite structures. The company has
equipped the majority of European satellites with lightweight, rigid and thermallystable structures. The range of missions
that RUAG is involved in includes the
ATV European space transporter, the
Alphabus and SmallGeo telecommunication platforms plus ESA science missions
such as Herschel/Planck or BepiColumbo.
Depending on the requirements of each
mission, the company employs different
technologies when developing satellite
structures. A good portion of these structures consists of sandwich-structured composites made from carbon-fibre reinforced
polymers, which are particularly lightweight yet still highly stable. The panels are
fitted with inserts for attaching equipment
such as instruments or sensors. A typical
communications satellite has more than
2,500 of these inserts. Up to now, the
aerospace industry had to position these
inserts manually.

The company's ground-breaking innovation has to do with the insert itself, the
positioning process and a newly developed machine: the Automated Potting
Machine (APM). The machine cuts the
panels, drills holes for the inserts, applies
adhesive to the new insert - which was
designed specifically for this purpose -
and puts it in position. In addition, the
machine creates a report recording all of
the relevant process parameters for every
single insert. Previously, these activities
were performed in individual steps on
various machines in different locations
and required significant manual effort.
Automation is now possible thanks to a
new insert, for which the company has
filed a patent. The insert was developed in close cooperation with the
University of Applied Sciences and Arts
Northwestern Switzerland. The partners
conducted
several studies and refined the automation of the insert process so that it
works reliably in industrial applications.
With the new process, the company
will be able to reduce panel production

64 jec composites magazine / No95 March 2015

throughput time by at least a month, resulting in significant cost savings. A general rule of thumb in satellite manufacturing states that every month trimmed
from throughput time saves 1 million
euros. At the same time, customers have
more leeway to adapt the insert patterns,
even fairly late in the process.
Two additional advantages are provided
by the new process. First, a stable,
automated process with higher precision
reduces the potential for error, producing additional savings of up to 50,000
euros per satellite structure. Second, less
adhesive is needed to bond the insert in

Fig. 1: Positioning the insert on the APM



JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015

Cover
Edito
Point of view: Raw materials - Quality, innovation, reliability and safety are exactly what we deliver
Contents
Companies & Business
Carbon fibre - “I am confident in the future of Zhongfu Shenying”
Automotive - “Composites are going to be more important again with the batteries...”
Agenda of Events
Applications
Thermoplastics - Evaluating the viability of thermoplastic composite pressure vessel
Motorcycle - Epoxy adhesive for a Harley-Davidson motorbike
Thermoplastics - New GRP enclosure for extreme environments
Market
Europe - The European upturn continues
Reinforcement - Glass fabrics demand will grow
Natural fibre - Securing the supply of technical flax for the composite industry
SPECIAL JEC EUROPE 2015
12th International JEC Conferences: Knowledge and networking
The know-how to develop tomorrow’s lightweight production technology
JEC Innovation Awards Program 2015
Innovations report 2015: France, country guest of honor
Design
Automation
Insert
CNC router
Tooling
Design and testing
Research & Development
Short natural fibres - Study on short natural fibres for composites
Biocomposites - Adhesion between flax fibre and a biobased thermoset matrix
Technology & Innovations
Lightweighting - Meeting the challenges for lighter cars with innovative products
CFRP - Carbon composites: Material systems with improved mechanical behaviour for various industries
Epoxy - DFCM: a new step forward in composite mass production
Graphene - Graphene-based high-performance composites via plasma functionalisation
Thermoset - Reformable epoxy adhesive film
Sizing - «We are constantly developing new products»
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Cover
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 2
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Edito
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Point of view: Raw materials - Quality, innovation, reliability and safety are exactly what we deliver
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 5
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Contents
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 7
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 8
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Carbon fibre - “I am confident in the future of Zhongfu Shenying”
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 10
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 11
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 12
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Automotive - “Composites are going to be more important again with the batteries...”
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 14
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 15
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 17
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 18
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Thermoplastics - Evaluating the viability of thermoplastic composite pressure vessel
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 20
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 21
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Motorcycle - Epoxy adhesive for a Harley-Davidson motorbike
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 23
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 24
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Thermoplastics - New GRP enclosure for extreme environments
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 26
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Europe - The European upturn continues
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 28
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 29
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Reinforcement - Glass fabrics demand will grow
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 31
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Natural fibre - Securing the supply of technical flax for the composite industry
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 33
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - SPECIAL JEC EUROPE 2015
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 12th International JEC Conferences: Knowledge and networking
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 36
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 37
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - The know-how to develop tomorrow’s lightweight production technology
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 39
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 40
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 41
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - JEC Innovation Awards Program 2015
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 43
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 44
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 45
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 46
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 47
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 48
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 49
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 50
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 51
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 52
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Innovations report 2015: France, country guest of honor
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 54
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 55
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 56
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 57
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 58
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 59
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Design
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 61
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Automation
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 63
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Insert
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 65
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - CNC router
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 67
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Tooling
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 69
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 70
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Design and testing
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 72
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 73
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 74
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 75
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 76
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 77
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Short natural fibres - Study on short natural fibres for composites
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 79
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 80
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 81
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Biocomposites - Adhesion between flax fibre and a biobased thermoset matrix
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 83
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 84
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Lightweighting - Meeting the challenges for lighter cars with innovative products
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 86
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 87
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - CFRP - Carbon composites: Material systems with improved mechanical behaviour for various industries
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 89
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 90
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 91
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Epoxy - DFCM: a new step forward in composite mass production
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 93
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 94
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Graphene - Graphene-based high-performance composites via plasma functionalisation
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 96
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 97
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Thermoset - Reformable epoxy adhesive film
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 99
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 100
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 101
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Sizing - «We are constantly developing new products»
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 103
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 104
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 105
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - Index
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - In the world
JEC COMPOSITES MAGAZINE - Issue #95 - Special JEC Europe - March 2015 - 108
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