IUsed 1996 Ingersoll Automated Fiber Placement Machine
Retrofitted in 2005
1. Maximum Part Length ~ 58’
2. Maximum Diameter ~ 20’
3. Minimum Part Length ~ 12’
4. Rotational Center is 165” inches above the floor and 143inches above the bed.
5. Head is 32 x ¼” Slit Tape Tow. Creel and head travel together on a single platform is a better design for backing film
6. Head is on a boom that provides limited vertical centerline height adjustment.
7. ‘A’ axis travel = +/- 190 ‘B’ axis travel = +/- 35
8. J-Boom’s travel is -34° to +15°, total 49°
9. ANSI standard axis convention for a rotary tool or lathe type machine
10. Siemens 840 D control retrofitted in house by Spirit AeroSystems:
11. Ingersoll Front End Processor for real time data streaming to the 840 D Siemens
12. Delta Tau computer for head I/O and control
13. Several upgrades to the head but it is an older version and not current w/o spares
14. Creel has a new refrigeration system on it.
15. Creel has newer, but custom motors and controls and dancers – Limited or No spares!
16. Operator Rides the machine – Excellent for MR&D Good Head compaction Camera.
17. Qualified at 600 ipm cut/add with +/- 0.10 accuracy
18. Older Design head and trays with the creel probably limit higher speed.
19. Head has a -20F chiller for temperature control
20. Machine is designed for Round parts but will do large flat coupons
21. Tow path only has 7 touch points with dancers and all before going into the head.
22. Backing film removal is vacuum with a chopper and works quite well at these speeds.
23. Creel has two zones with new Honeywell temperature controls and chart recorders for Temperature and Humidity monitoring.
24. Dancer system is a responsive system, but has limited or no spare parts. A high pressure intensifier and accumulator for the head air valve systems is installed.
25. Air valves on the head are older series valves and not the current technology
26. Electrical cabinets are composed of 8 ea. Free standing 30” x 80” ganged together with all electrical controls, drives etc.
27. Rotator Spindle Interface is a simple 6 bolt pattern with a large pin in the center
28. Rotary axis gearbox systems are dual motors on both head and tail stock
29. The rotary axis was detuned to use an 85,000 lb. mandrel for a test part.
30. Rotary columns are not really strong enough to do 85,000 lb. mandrels because at that weight the head and tail stock natural frequency is 2 Hz.
31. Custom Foundation Required
32. Foundation will require Heavy Steel Imbeds for machine anchorage points
33. Electrical Documentation for the original machine is available
34. Backup copies of the machine control software and all computers is available.
35. Cable distance is the cable track for full machine travel plus the underground distance to the control cabinets about 4’ behind the machine.
36. It is expected to require up to 8 ea. 40’ flat bed semi trucks to load all the equipment.