automated composite processing solutions -...
TRANSCRIPT
Solutions & Applications
, Turning
, Milling
, Powertrain
, Composites
, Process Technology
, Maintenance
, Automation & Software
, Core Componentsw w w. m a g - i a s . c o mThe machines shown are examples. Actual machines may vary based on selected optionsCS4200(02DE)en/1000/03.10
Automated Composite Processing Solutions
MAG is a leading machine tool and systems company serving the
durable-goods industry worldwide with complete manufacturing solutions.
The company offers a comprehensive line of equipment and technologies
including process development, automated assembly, turning, milling,
automotive powertrain production, composites processing, maintenance,
automation and controls, and core components. Key industrial markets
served by these technologies include aerospace, automotive and truck,
heavy equipment, oil and gas, rail, solar energy, wind turbine production
and general machining.
With manufacturing and support operations strategically located worldwide,
MAG ranks as a leader in the capital equipment market. A growing number
of leading international companies are relying on the impressive innovation
power of MAG to assure their technological leadership and prepare for
future challenges.
MAG Americas
MAG IAS, LLC
Olympic Corporate Center l
3940 Olympic Boulevard
Erlanger, KY 41048
U.S.A.
tel +1 859 534 4600
fax +1 859 669 1898
MAG Europe
MAG IAS GmbH
Stuttgarter Straße 50
73033 Göppingen
Germany
Tel. +49 7161 201 0
Fax: +49 7161 201 353
Composite ApplicationsManufacturing Processes
Advantage of Composites
Due to their versatile and excellent material properties, the importance of
composite materials in manufacturing has never been greater. Significant
features of composite materials are their high specific rigidity and strength,
low weight and high corrosion resistance. Because of the ability to build
extremely strong, but lighter weight parts, composites are used in many
different industries including aerospace, wind energy and automotive.
Automated Composites Solutions – made by MAG
Worldwide, only a handful of machine tool manufacturers have the experience
and knowledge required to produce manufacturing systems for components
made of composite materials. MAG has over 30 years of experience in the
development and production of automated composites processing equipment
and is known as the technology and performance leader throughout the
aerospace industry. With over 120 installations across the globe, we have
more tape layers and fiber placement systems in operation than the com-
bined total of all other suppliers of this equipment.
Expanding Into Growing Composites Markets
The strength, durability and versatility of composites is recognized in other
key manufacturing sectors including energy, automotive and construction.
We utilize industry-specific technology, along with our own extensive
systems development expertise, to bring the advantages of composite
materials to the automotive and wind energy sectors.
European Composites Center
MAG has had great success in the manufacturing and development of tape
laying and fiber placement systems in the U.S. for many years. With the
growing significance of composites technologies in Europe, MAG opened a
new composites center in Germany, at the end of 2009. This location
will serve as a manufacturing and development site for composites
applications, in co-operation with OEMs as well as producers of
composites components and materials, for Europe.
MAG is the “Supplier-of-Choice” to leading aircraft producers around
the world. Whether choosing automated composites processing equipment
or related machine tools such as robust, titanium processing machines or
specialized solutions, our equipment achieves superior results.
Australia Hawker de Havilland
Belgium SABCA
Brazil Embraer Air, General Electric
Canada Bombardier, NRC Institute,
Magellan Aerospace, Heroux-Devtek
China Chengdu Aircraft, Shanghai Aircraft,
Xian Aero Engine, Xian Aircraft,
Shenyang Aircraft, Liyang Aero Engine
France Airbus
Germany Airbus
Hungary General Electric
Indonesia IPTN
Israel Israel Aerospace Industries
Italy Alenia
Japan Fuji Heavy Industries,
Kawasaki Heavy Industries,
Mitsubishi Heavy Industries
Korea Korea Aerospace Industries, Korean Airlines
Spain Airbus, EADS CASA
UK Airbus, BAE Systems, Bombardier,
Magellan, Rolls-Royce
USA ATK, Bell Helicopter, Boeing, General Electric,
GKN Aerospace, Giddens Industries,
Goodrich, Hawker Beechcraft, HITCO,
Lockheed Martin, NASA, Northrop Grumman,
Raytheon, Spirit Aerospace, Vought Aircraft
02 | 03
Aerospace Composites Leader
MAG is your solutions provider for automated composites processing
equipment and the leader in manufacturing tape laying machines and fiber
placement systems for the aerospace industry.
Highest floor-to-floor production rates
, Unbeatable processing speed
, Highest quality available
, World’s largest installed base
, Broadest range of parts and sizes
Composites Applications:
, Fuselage
, Wing skins
, Engine nacelle components
, Horizontal and vertical stabilizers
, Military aircraft inlet ducts
, Space launch vehicle components
CHARGER™ Tape Laying Systems
MAG CHARGER Series includes both contour and flat tape layers
available in high rail, low rail and bed type configurations to meet
production and facility requirements. The CHARGER series of products
are all compatible with ACES® software.
VIPER® Fiber Placement Systems
The VIPER platform of machines combines the advantages of tape laying
and filament winding with advanced computer control and software to
achieve unmatched production capabilities for a wide variety of complex
composites parts. The VIPER series of products are all compatible with
ACES software.
04 | 05
Aerospace
Small Flat Tape Layer
Robotic VIPER®
VIPER® fiber placement systems 1200 / 4000 / 6000
VIPER® 7000 for Aerospace
CHARGER™ low and high rail tape layers
06 | 07
Wind Turbines: Efficient Machining and Manufacturing
of Components
MAG offers a wide range of machines and technology solutions for large
parts and highest precision for components of wind turbines and thus
improves blade quality, increases productivity, reduces material waste and
greatly improves employee health and safety.
VIPER® 7000 Vertical Gantry
, The gantry configuration is sized for blade shells, spars, spar caps
and shear webs
, Vertical six-axis gantry that laminates 32 lanes of carbon or glass
prepreg tows
, Generous material carrying capacity and high lay-up rates add speed
and reliability to automated blade manufacturing resulting in quality,
wrinkle-free lamination
, Lamination of blade shells – carbon fiber or glass
, Lamination of spars, spar caps – carbon fiber or glass
, The programming process options include: fiber steering, parallel
path and fixed
Rapid Material Placement Systems (RMPS)
, Automated blade molding system for the production of laminates for
blade skins and spars
, Capable of spraying in-mold coatings, dispensing glass and carbon
fiber materials and adhesives
, Modular platform capable of dispensing multiple material width
, Compatible with our ACES software
Quick-Cure Molding System
New patent-pending quick-cure molding system offers a versatile concept
to increase productivity while maintaining quality
Automated Root End Machining for Rotor Blades
, Automated adjustment towards rotor blade
, Machining processes: sawing, milling, drilling and trimming
, Assembly process for T-Bolts
, High modularity to increase productivity
, Flexibility and quick changeover
Quick-cure molding system
VIPER® 7000 for Wind
Automated root end machining
Wind
Rapid Material Placement System (RMPS)
08 | 09
Revolutionary Manufacturing Solutions
MAG utilizes the advantages of composite materials for efficient
manufacturing in the automotive industry offering world class, automated
composites solutions to produce parts for automotive applications.
, Consulting and project management of turnkey solutions
, Manufacturing systems/plants for thermoset and thermoplastic
materials utilizing compression molding processes (SMC, LFTD)
and continuous fiber manufacturing processes
, Consulting in process and material selection (LFTD, SMC, RTM)
, Process expertise
, Turnkey manufacturing systems
, Forming, part handling and machining of components
, High strength structural underbody components and
Class A body panels
, Laminate generator for structural composites parts
CNC cutter unit
Turnkey SMC production line
Continuous laminating line
Slitting module
Automotive
CM100 Control
With the largest number of users worldwide, our ACES® off-line programming software consistently receives superior customer satisfaction ratings
Your Single Source for Maintenance, Productivity Solutions & Logistics
MAG‘s software business unit, e-tekx leads the industry with control
and off-line programming software platforms compatible with our
CHARGER Tape Layers, VIPER Fiber Placement Systems and Rapid
Material Placement System (RMPS).
ACES® – Advanced Composites Environment Suite
ACES is our proprietary programming and simulation software tool for tape
laying and fiber placement.
, Simulation capabilities to prove part design and maximize
machine performance
, Sophisticated coverage analysis
, Compatible with CATIA V4 and V5, CATIA CWB/CD3 and FiberSIM
, Provides a variety of path generation types
, Multi-core processor support improves throughput x 8
Powerful CM100 Control
, Only control specifically designed for composites
, Powerful, yet easy to use
, Open architecture design
, Accurate lay-up with programmable control
, Includes Observer part history for maximum productivity
Freedom eWARE™ – Suite
For manufacturers interested in improving efficiency, productivity, and
profitability, MAG’s e-tekx software group offers the most comprehensive
and powerful suite of data acquisition and analysis tools in the industry –
FreedomeWARE™. Built on the concept of a modular, scalable, software
platform that provides a wide-ranging tool-set for data acquisition, asset
management, process optimization, and predictive maintenance strategies,
eWARE™ is unique in that it can interface to any industrial asset without
the need for modification of equipment ladder logic or part programs.
eCONNECT™ control resident data collector
eLOG™ present, analyze and report critical asset data
eSCOPE™ real time maintenance data & analysis utility
eNERGY™ monitor and analyze energy consumption
eMONITOR™ condition based monitoring utility
eCELL™ control for automated palletized manufacturing
e-tekx Software
10 | 11
eCONNECT™
eSCOPE™
eNERGY™
eMONITOR™
eCELL™
eLOG™
Maintenance & Renewal Solutions
MAG is your single source for maintenance and productivity solutions
designed to optimize plant operations. With our comprehensive product and
service programs manufacturers achieve maximum equipment availability
and utilization reducing their cost per piece.
Maintenance & Support
, Health checks
, Preventive maintenance
, Machine certification
, Repair and exchange services
, Rebuild, retrofit and remanufacture services
, Machine installation and relocation
, 24 /7 parts and service
24/7 Service Parts
, Genuine OEM replacement parts
, Central warehouse with 24/7 service
, Online parts store at www.mag-ias.com
, Safety-related components
, Spare part packages and unit assemblies
, Repair and exchange service
Preventive Maintenance
, Programs for preventive maintenance
, Machine certification and inspection
Customer Service
, World-class call center support
, Service operations worldwide
, Field Service
, High-qualified, factory-trained technicians
, Interactive technical support
, Maintenance training programs
, Service contracts
Retrofit, Rebuild, and Remanufacture
, Retrofit control and drive systems
, Pre-engineered kits available
, Remanufacture a machine to its original
factory specifications
, Relocation of machines and complete systems
, Repair and exchange units
Productivity Solutions
MAG is your single source for productivity solutions. We can increase
the productivity of your existing machinery, and apply high-performance
tooling and metalworking fluids to your new machine tool applications,
giving you the competitive edge you need.
CYCLO CUT Tooling & Tooling Systems
, Rotary cutting tools made of solid carbide, brazed carbide, and high
speed steel
, Indexable inserts and cutter bodies
, CAT, BT and HSK tool holders
, Boring and backspotfacing tooling systems
, Tooling accessories and set-up equipment
CYCLO COOL Coolants & Equipment
, Synthetic cutting fluids
, Semi-synthetic cutting fluids
, Soluable oils for enhanced machining
, Specialty cutting fluids for machining high-temp alloys
, Minimal Quantity Lubrication (MQL)
, Production cleaners
, Corrosion inhibitors
Process Technology
, Process optimization
, Clamping and automation concepts
, NC-programming
, Machine capability studies
, Production support
Software
, Freedom eWARE Suite
, CAD / CAM Software
, Shop Pro / Cut Pro
, Omative Adaptive Control
Logistics
MAG offers a comprehensive logistics service to increase your
productivity. Our extensive product range is tailored to meet all your
manufacturing needs, providing a complete service package for the life
of your machine.
Tool Management
Fluid Management
Relocation Management
Freedom eLOG
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- Cycle 38.3%
- Equipment 62.1%- Overall 62.1%
- Equipment 38.3%- Potential 61.7%
- In Cycle 38.3%- Process 0.0%- Repair 23.4%- Delay 0.0%- Sched Down 38.3%- Shutdown 0.0%
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