The landscape of advanced manufacturing is undergoing a significant transformation, with advancements in robotic systems driving unprecedented levels of precision and flexibility. A prime example of this evolution is the collaboration between Siemens and Ingersoll Machine Tools, which has enabled a tenfold increase in the positional accuracy of off-the-shelf robots, revolutionizing how complex components are produced for demanding sectors like aerospace. This strategic partnership is not merely about integrating existing technologies; it is about pushing the very boundaries of what industrial robotics can achieve, responding directly to the market’s growing demand for nimble, transferable, and highly adaptable manufacturing solutions.
As highlighted in the accompanying video, the traditional constraints of manufacturing are being redefined through innovative applications of advanced robotics and sophisticated control systems. The synergy between Ingersoll’s expertise in automated fiber placement and 3D printing, combined with Siemens’ cutting-edge CNC controls and simulation software, is creating powerful tools capable of tackling some of the most intricate production challenges. This evolution is particularly critical in industries where structural integrity and geometric precision are paramount, such as the aerospace sector, where components often require flawless execution to ensure safety and performance.
Revolutionizing Manufacturing with Robotic 3D Printing
Initially, Ingersoll focused its efforts on aerospace applications for automated fiber placement and robotic 3D printing. However, the market’s enthusiastic reception of these advanced capabilities has led to significant pull from general industry sectors, seeking more agile and flexible manufacturing processes. Businesses are increasingly looking for systems that can be easily transferred between different production locations and adapted to a wide variation of part geometries without extensive retooling or lengthy setup times. This demand underscores a broader industry trend towards versatile production platforms that can respond quickly to changing design specifications and market needs.
Robotic 3D printers offer a compelling entry point into demanding markets like aerospace, particularly for parts that do not necessitate the massive scale of traditional gantry machine tools. While the aerospace industry is often associated with extremely large components, there are countless smaller, complex parts requiring the highest structural integrity where robotic additive manufacturing excels. These robotic systems are designed to bridge the gap, providing precision and strength for components that benefit from additive manufacturing’s design freedom but require the positional accuracy traditionally found only in larger, more rigid machine tools. The flexibility of a robot’s multi-axis movement allows for complex geometries and internal structures not possible with conventional methods.
Ingersoll’s Dual Robotic Solutions and Siemens’ Control Prowess
Ingersoll offers a strategic differentiation in its robotic product line, featuring both standard and inverse robotic solutions. The standard robotic operations are typically better suited for larger components, leveraging their reach and payload capacity for substantial projects. Conversely, smaller parts often lend themselves exceptionally well to Ingersoll’s inverted robotic process due to its inherent agility and speed, making it highly efficient for rapid production cycles and intricate designs. This dual approach ensures that a wide spectrum of manufacturing needs can be met with optimized robotic solutions, preventing over-engineering for smaller parts and providing robust capabilities for larger ones.
The industry’s push for robots to perform at the same level as gantry machine tools presents significant challenges, particularly concerning accuracy. Siemens plays a pivotal role in overcoming these challenges by providing advanced CNC controls that transform industrial robots into true CNC machines. By marrying industrial robots with sophisticated CNC controls, Siemens enables unprecedented levels of precision and repeatability. Michael Falk notes that the shift in the CNC market towards robotic machining motivated Siemens to integrate their robust control systems with industrial robots, thereby unlocking new dimensions of performance previously unattainable.
Achieving Unprecedented Positional Accuracy and Reliability
One of the most critical aspects of the Siemens-Ingersoll partnership is the dramatic improvement in positional accuracy. Traditionally, industrial robots have exhibited decreased accuracy compared to their larger gantry machine tool counterparts, a limitation that has historically restricted their application in high-precision manufacturing. However, with the updated Siemens packages, the positional accuracy of an off-the-shelf robot can be increased tenfold, positioning them squarely within the realm of high-precision machining. This advancement is a game-changer for industries where every micron matters, ensuring components meet stringent quality standards.
This remarkable accuracy is further bolstered by Ingersoll’s in-house simulation package, which heavily utilizes Siemens tools. The Siemens VNCK (Virtual Numerical Control Kernel) allows for the complete simulation of robotic motion, identifying potential issues and optimizing processes before any physical production begins. This “digital twin” approach ensures that operations run exactly as planned on the machine, eliminating surprises and significantly reducing setup times and material waste. Furthermore, the Siemens PLC (Programmable Logic Controller) is integral to active, continuous monitoring of the manufacturing process, providing real-time data and insights to ensure consistent performance and reliability throughout the production cycle.
Complex Systems, Simplified Control
The complexity of modern robotic systems, such as machines with six axes of movement plus an additional table, demands an exceptionally powerful control system. The Siemens CNC control is designed with sufficient robustness to manage such intricate degrees of freedom, operating the robot as a fully integrated CNC machine. This advanced control capability extends beyond mere motion control; it also integrates seamlessly with simulation software, allowing Ingersoll to thoroughly verify part programs and component designs before any physical layering or machining commences. This pre-validation step is crucial for complex aerospace components, where errors can be incredibly costly and time-consuming.
The collaboration ensures that customer demands for accuracy, repeatability, durability, and reliability are not just met but exceeded. Jason Melcher emphasizes that the partnership between Ingersoll and Siemens provides a productive solution that businesses can confidently integrate into their strategic plans. This joint offering delivers robust and dependable manufacturing capabilities, allowing companies to innovate and expand their operational horizons. The ongoing focus on “innovation, innovation, innovation” as a core tenet of this partnership drives the continuous development of new technologies and further pushes the envelope of what’s possible in advanced robotics for aerospace and beyond.
Charting the Course: Your Advanced Aerospace Robotics Q&A
What is the main goal of the partnership between Siemens and Ingersoll?
The partnership aims to greatly improve industrial robots for advanced manufacturing, especially by making them much more precise and flexible. This allows them to produce complex components for demanding sectors like aerospace.
How has this partnership improved the accuracy of industrial robots?
Through their collaboration, Siemens and Ingersoll have managed to increase the positional accuracy of off-the-shelf robots by tenfold. This makes them precise enough for high-quality manufacturing tasks.
What types of advanced manufacturing processes do these improved robots support?
These advanced robots are revolutionizing processes like robotic 3D printing and automated fiber placement. They are particularly useful for creating complex, high-precision parts for industries such as aerospace.
What is Siemens’ main contribution to this collaboration?
Siemens provides cutting-edge CNC (Computer Numerical Control) controls that transform industrial robots into highly precise CNC machines. They also offer simulation software to plan and optimize robotic movements before production starts.
Why is increased accuracy so important for these robots in industries like aerospace?
Increased accuracy is vital because aerospace components require flawless execution, structural integrity, and geometric precision for safety and performance. It ensures parts meet extremely strict quality standards where every tiny detail matters.