Automated and Flexible Clamping of Turbine Blades
for the Measurement Process

Challenge: Variability and Complexity of Geometries

Turbine blades, whether for aviation or gas turbines, are manufactured in a wide variety of shapes and sizes. This high variability presents a particular challenge, as the blades need to be repeatedly fixed during the manufacturing and inspection process. Due to their highly complex geometries, conventional clamping tools are often insufficient, resulting in high costs for the development and production of specific clamping fixtures.

In our specific customer application, various types of blades need to be picked by a robot from a fixture and then fed into a measurement cell, where they must be securely fixed for the automated measurement process.

Solution: The Flex-Clamp System by MATRIX®

The Flex-Clamp System by MATRIX® offers an innovative solution to this challenge. This adaptive clamping system can be mounted as an end effector on robot grippers or used as a flexible support. It consists of a multitude of spring-loaded MATRIX pins that immediately adapt to any workpiece geometry when the gripper is closed. After adapting, the pins are pneumatically locked to maintain the negative shape of the workpiece and apply gripping force.

A special feature of the Flex-Clamp System is the pressureless locking, which ensures secure fixation of the workpieces even in the event of a pneumatic system failure. Turbine blades of various kinds can be safely gripped or fixed with just one adaptable gripping system without causing damage—whether at the blade or the fir tree profile.

Advantages and Conclusion

The Flex-Clamp System by MATRIX® revolutionizes the handling of changing and complex parts by eliminating production stoppages for gripper changes. The need for the production and storage of specific gripper jaws is eliminated, saving significant costs. Additionally, the high flexibility allows for the complete replacement of gripper stations.

Summary

The Flex-Clamp System significantly facilitates the automated and flexible clamping of turbine blades in the measurement process. It enables the safe and efficient handling of various types of blades without the need for specific clamping fixtures to be developed and stored. This innovation represents a significant advancement in manufacturing and inspection technology, offering companies the opportunity to optimize their processes and reduce costs.

Revolution in the measurement process: The programmed fixture Flex-Station

In the aviation industry, where precision and efficiency are crucial, measuring complex milled aluminum parts poses a tremendous challenge. Previously, in our customer application for over a thousand differently shaped parts, several specific measuring fixture were needed for each part–an expensive and logistically demanding process. The goal is now to measure all types of workpieces efficiently and repeatably with a single, flexible, and programmable fixture, with minimal setup effort and fully automated.

The challenge: Complexity and cost

The conventional method of using specific measuring fixture for each workpiece not only leads to high costs in design, manufacturing, and logistics but also to a tremendous amount of time. Each workpiece must also usually be measured in at least two positions, further increasing the complexity.

The solution: The Flex-Station by MATRIX

The Flex-Station by MATRIX sets new standards in the field of fixtures and workpiece carriers. Thanks to the advanced MATRIX software, 3D data of the workpieces in formats such as .STP, .STEP, or .STL can be read into the software and positioned on the well-known MATRIX pin modules. The software calculates the pin positions, which are then saved as a program. These programs can be automatically called up and executed by the plant control system, allowing the pins to be set with high precision and repeatability. Subsequently, the created fixture is loaded by a robot.

Benefits and optimizations

With the introduction of the Flex-Station, specific fixtures can be completely replaced. This leads to a significant reduction in personnel costs for the design of specific fixtures and in manufacturing and storage costs. The flexibility and programmability of the fixture minimize the setup effort and maximize efficiency in the measurement process.

Conclusion

The implementation of the Flex-Station in the measurement process of the aviation industry illustrates how process optimizations and cost savings can be achieved through innovative technologies. This technology enables flexible, efficient, and precise measurement of complex workpieces and sets a new standard in the automation of measurement processes.

Extract from MATRIX software

The workpieces in the images do not correspond to the parts described in the customer application.

The Flex-Clamp MINI System

In today‘s fast-paced production landscape, efficiency and precision are essential, especially when it comes to handling and assembling small parts. A challenging scenario in this field is the automated assembly of electronic connectors, which come in various shapes and sizes. The task is to automatically pick up these connector housings from a vibrating conveyor and position them precisely in front of an assembly station, which then inserts the cable. A particular challenge here is that a button on the connector must not be pressed during the gripping process.

The Challenge: Diversity and Precision

The variety of connector shapes and sizes presents a significant challenge that requires a flexible and precise solution. Moreover, the gripping system must be able to optically recognize the parts and handle them without damage or malfunction. This requires an innovative solution that can adapt to the different contours of the workpieces without affecting critical components like the mentioned button.

The Solution: Flex-Clamp MINI System

a flexible gripping solution that instantly adapts to any workpiece contour, absorbs forces, and can move parts with repeat accuracy. This system allows for the complete replacement of part-specific gripper jaws, thereby eliminating production downtime due to gripper changes. Such innovation not only saves valuable time but significantly optimizes the entire assembly process of the end customer.

Thanks to the precise form-fit that the Flex-Clamp MINI System enables, a very low gripping force is needed. This is a crucial advantage, as it means the workpieces are not deformed, and critical operating elements on the connectors remain untouched. The system thus guarantees safe and efficient handling of the connector housings, without the risk of damage or accidental pressing of the button.

Conclusion

The Flex-Clamp MINI System by MATRIX® represents a significant advance in robotic gripper technology. It successfully addresses the challenges associated with the diversity and required precision in the automated assembly of electronic connectors. By implementing this system, companies can significantly improve their assembly process, increase efficiency, and boost productivity. It is a shining example of how innovative technologies are driving Industry 4.0 forward and elevating production processes to a new level.