The best ideas factory - for technology and people.
We are helping to shape the megatrends of mobility, the environment and society and are setting new standards as a machine engineering company.
The aviation industry is of central strategic importance to us. From the fiber to the tested component to the fully assembled aircraft structure - under this motto, our experts develop pioneering solutions and technologies.
LAMINATION
High-performance laying systems
Fiber-reinforced plastics are becoming increasingly important, particularly in the aviation industry. The aim is to produce composite components in large quantities with consistent high quality.
A key process here is the automatic placement of the fibers. We are continuously developing new technologies and system concepts to meet the high requirements. Regardless of the input material, Fill offers a wide range of systems - from direct fiber placement to complex pick & place applications.
In addition to reliable system technology, programming and quality assurance also play an important role. With the TAPE STUDIO software tool developed by Fill, laying systems can be operated easily, quickly and reliably - from the CAD geometry directly to the machine. The CYBERNETICS VISION image processing solution is used to check the laying quality.
PREFORMING
Automated stringer manufacutring
The HOT DRAPE FORMING LINE increases productivity and reliability in the production of CFRP stringers. The production cell consists of an automatic tool storage system, the forming station and an assembly station in which all laminates are processed into stringers and finally applied to the skin.
In addition, individual sub-processes are automated in order to reduce waste and increase performance. The result is a high level of reproducibility in the production of stringers and a significant increase in the productivity of the overall system.
The CYBERNETICS PRODUCE HDF software application developed by FILL records the history of the components across the entire process chain. Based on this data, the production progress is visualized in real time and thus supports not only the process planners but also the operators in their tasks.
MULTIPROCESS
RTM Automatisierung
As a system integrator, we offer our customers customized system concepts and assume overall responsibility for even the most complex automation processes.
Intelligent process control and high utilization of the individual system components increase the reliability and efficiency of the production system.
In this specific case, the entire manufacturing process is divided into sensible individual steps. This shortens the occupancy time of the presses and therefore also the cycle time considerably. The result is high reproducibility and a significant increase in productivity in RTM production.
The CYBERNETICS PRODUCE software application developed by FILL records all process-relevant data and ensures convenient access to the history of the components across the entire process chain.
THERMOPLASTIC COMPOSITES
Process automation
Short cycle times, weldability and recyclability are the main advantages of thermoplastic composites.
A 2D stack is created automatically from the 3D model. This is produced at maximum speed in the high-performance MULTILAYER lay-up system. In the CONSOLIDATION UNIT, the pre-joined semi-finished products are consolidated under the influence of thermal energy and pressure. Before the shaping process, the stack is heated in an infrared oven. It is then brought into the final 3D contour either in the injection molding system or in a forming press.
As the general contractor, Fill assumes overall responsibility for the complete automation process.
ACCUBOT
NC-robot for high precision application - the next level in process automation with robots
High-precision mechanics, output-side measuring systems, unique real-time compensation and a SIEMENS Sinumerik ONE controller: In combination, these features take the ACCUBOT to previously unattained accuracy ranges in terms of positioning and path accuracy.
The use of NC-controlled robots opens up a wide range of applications - from NDT testing, automated drilling and tape laying to the milling of large components. There are no limits to the areas of application, whether on a linear rail on the floor or on a mobile platform.
The high flexibility of the robot cell is made possible by FILL STUDIO - an intelligent, efficient and easy-to-use software solution that can be used to map different processes on a production cell.
TRIMMING & METROLOGY
Flexible component machining
The use of high-precision NC-controlled robots enables flexible and efficient processing of composite components.
In addition to the trimming process and setting up the customizable clamping device, the production system's tasks also include the geometric measurement of structural components made of lightweight materials. The ACCUBOT TRIMMING takes on the central role here.
The multimodal approach of the system concept allows various functional units for trimming, measuring and setting up the fixture to be coupled to the robot fully automatically using the FLEXCHANGE interchangeable coupling.
The high flexibility of the robot cell is made possible by the FILL STUDIO software application - an intelligent, efficient and intuitive-to-use software solution that can be used to map different processes on a production cell.
NON-DESTRUCTIVE TESTING
Multimodal - maximum cost-effectiveness
As a system integrator, Fill offers its customers a perfectly coordinated overall concept. Ultrasonic electronics with exceptionally high dynamics and integration into the FILL STUDIO software package deliver the best test results in throughtransmission and pulse-echo operation.
A direct interface for offline programming allows scan programs to be simulated in FILL STUDIO. The integrated native digital twin makes this possible.
The multimodal approach with a flexibly configurable, fully automatic interchangeable coupling (FLEXCHANGE) allows other applications such as X-RAY or METROLOGY to be integrated.
In addition to the inspection processes, reproducible clamping of the components plays a central role. The DIGITAL RIGGING ASSISTANT is our solution to eliminate potential set-up errors, and the clamping fixtures can be pre-set fully automatically if required.
NDT & METROLOGY TOOLBOX
Application-independent and kinematically autonomous
As a central framework for combining all types of kinematics with the whole range of applications, the FILL STUDIO software generates maximum system viability for the customer.
Be it ULTRASONIC, X-RAY, or METROLOGY – all modes are controlled by one software tool with a multimodal approach. Minimum training outlay, optimum userfriendliness, and maximum flexibility are additional benefits of this tool.
The unique architecture shows the system operator only the necessary information, while the whole range of functions is available to experts.
AUTOMATED DRILLING
Flexible and economic drilling system
The use of high-precision NC-controlled robots enables flexible and efficient machining of structural components. The ACCUBOT is mounted on a high-precision and rigid linear axis from Fill to expand the machining area.
In addition to the drilling process, the set-up of the clamping device is a decisive factor in increasing productivity. The component holders are stored centrally in a rack and are attached to the corresponding interface by the robot.
The individually adaptable clamping device can be used for a variety of different components, which enables economical and reliable clamping and machining.
Intelligent technologies - such as vibration-assisted drilling (VAD) - can be integrated if required. This reduces the cycle time and enables the use of sensor signals for inline quality assurance or the detection of tool wear.
AUTOMATED ASSEMBLY
Fully automated - everything from a single source
The constant demand for flexible automation systems for the assembly of aircraft structures is driving the development of innovative manufacturing concepts. The focus here is on the seamless integration of various processes - both hardware
and software.
Production systems from Fill enable the use of automated processes such as drilling, riveting, activation, sealant application, provision, and positioning of components.
In addition to the automated processes, the precise positioning and fixing of the components also play a key role in the final quality of the components.
As a system integrator, Fill offers its customers a perfectly coordinated overall concept - from tooling to process automation through to the digital twin of the entire system.
METROLOGY
In relation to reality: Future-oriented metrology applications
METROLOGY.REFERENCING
is used for automatic component position detection in the machining area.
METROLOGY.VALIDATION
Automatic type recognition for different components. The application ensures maximum process reliability, especially for component families with few distinguishing features.
METROLOGY.RECONSTRUCTION
In reality, CFRP components often differ from the CAD model. The METROLOGY.Reconstruction tool scans the component and transfers the data to an offline programming system as the basis for creating the machining program.
METROLOGY.MEASURING
High-resolution sensor systems generate high-precision component data, which is used for geometric measurement. The measuring reports are then generated automatically.
Use of innovative technologies and many years of experience in specialist machine engineering and implementing complex projects make Fill a competent and reliable partner. Our strength lies in the identification and practical application of synergies from diverse branches of production.
If you are seeking the best solution, shape your future with Fill.
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