Total Solution for Carbon Fiber Manufacturing

The World’s Most Comprehensive Range of Solutions for High Productivity Composite Manufacturing Systems

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

6-7 Torresfiberlayup8-9 Torreslayup10-11 Torresmill® and Torrestool®

12-13 Torrespanex14-15 Torresdrill and Torrestool®

16-17 Torrestool®

18-19 Torressonic20-21 Flexible Drilling Head22-23 Special Projects

On Composite24-25 Software

2 3

Total Solution for Carbon FiberManufacturing

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING 4 5

In the face of FragilityMaximum Precision

MTORRES has developed overthe years the widest range ofsystems to automate, with thehighest flexibility and productiv-ity, the composite componentsmanufacturing process.

Ranging from Automatic TapeLaying and Fiber PlacementSystems for lamination,Ultrasonic Cutting, Routing andDrilling with Flexible ToolingMachines for net trimming,Ultrasonic Inspection for nondestructive test to AutomatedAssembly Jigs, MTORRES pro-vides the most comprehensive,productive and well provenrange of solutions.

MTORRES strong Engineeringand Project Management capa-bilities ensures the capacity todefine, manage and successful-ly implement complex integrat-ed projects providing Turn Keyglobal solutions to our cus-tomers.

That powerful engineeringcapacity allows the develop-ment of a number of cus-tomized special projects, aswell as an array of sophisticatedand advanced software solu-tions, for easy programming ofLamination Equipment, SpringBack Compensation for com-posite machining applications,HMI, Postprocessors, etc.

Our products cover all types of composite materials, CarbonFiber, Glass Fiber, Prepreg andDry Materials, Unidirectional,Fabric, Thermoplastic, Ther-moset, as well as processessuch as Lamination, Resin Infusion, out of Autoclaveprocesses, Ultrasonic Cutting,Routing and Drilling, NDT and Assembly.

Sectors of activity range fromAerospace , Naval, RenewableEnergy to Transportation.

Automatic

Fiber Placement

Machine

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

TORRESFIBERLAYUP

6 7

OPTIONS· Automatic splicer· Automatic miss add/miss cut· Ultrasonic cutting system· Wireless pendant· Automatic polyethylene

disposal

The TORRESFIBERLAYUP hasbeen specially designed forextremely high speed andhigh productivity fully auto-matic process to fabricate highcontour carbon fiber parts.

Applications include manufac-turing of flat, mild curvature aswell as high contour carbonfiber components.

The TORRESFIBERLAYUP is amachine designed to providethe highest productivity when itcomes to fabricate high contourcarbon fiber aircraft compo-nents, although a 2D for highspeed flat lamination, providinghuge scrap material savings is also available.

Its unique tow cutting andadding system at full speeddesign concept allows themachine to cut, add and laydown consistently and accurate-ly at 60 mpm (2,500 IPM),ensuring the highest productivi-ty fiber placement solution available in the market.

It is a modular concept systemthat allows the design and deliv-ery of virtually any configurationof machine in terms of MachineArchitecture (Column, Gantry,Cantilever type), with or withoutdifferent loads Head Stock/TailStock, number of tows, as wellas the tow width (1/8'', 1/4'', or1/2'' ) and machine size.

A highly advanced and sophisti-cated programming/simulationsoftware package, TORFIBER,allows the programmer to generate, simulate and analysethe part program, within a CATIA

environment, before the MTORRES provided postproces-sor generates the CNC program.

Automatic

Tape Layer

Machine

8 9MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

TORRESLAYUP

OPTIONS· Scrap saving software

(Multitape option only)· Mould scanning system· Laser contour marking

OPTIONS· Ultrasonic cutting system· Multitape· Automatic defect detection

system· Mould deviation

compensation system· Automatic knife calibration· Automatic knife cleaning

The TORRESLAYUP is an 11axes Gantry CNC tape layermachine specially designedfor high speed tape laying ofcompound contoured aircraftstructural components.

Furthermore, there is oneunique and remarkable optionfor flat components only, whichlays down simultaneously 4x150mm (4x6”) tapes, providing theproductivity of a 600 mm(24”)wide band keeping thescrap within the 150 mmm (6”)wide tape levels.

Additionally, the TORRESLAYUP

is the only available tape layer in the market that has proven to lay down successfully theCooper Mesh as well as GlassFiber material.

Optionally, an Ultrasonic Cuttingsystem built in the head, may cutthe solid laminate after laying to formats avoiding the need of a dedicated machine for thispurposes.

A highly sophisticated simulationsoftware package, TORLAY, allowsthe programmer to simulate andanalyse and modify every tape,ply, layer and part associatedparameter properly, before aMTORRES supplied postprocessorgenerates the CNC program. Inaddition, a Part History softwarepackage is provided, to keep control of production relevantevents.

TORRESLAYUP can be built in various sizes to meet customerrequirements.

The TORRESLAYUP is the leadingTape Layer reference in theIndustry in both 2D and 3Dworking modes.

Different machine architecturesare available, Gantry, Column,Cantilever, robot, etc. workingover a vacuum table, lay up toolor rotary mandrel.

The particular tape laying headdesign provides the best com-pacting results in the market,avoiding any debulking opera-tion while fabricating a part.The TORRESLAYUP standardhead runs with 300 and 150 mm(12'' and, 6'') wide tape beingoptional 75 mm (3”) tape.

A Multitape option, unique inthe market, offers a head capa-ble of running different reels oftapes at the same time. The same head can handle dif-ferent Multitape configurations,1x150 mm, 1x300 mm, 4x75mm or 2x150 mm (1x6”, 1x12”,4x3” or 2x6”) to provide thecapability to lay down severaltapes simultaneously.

In this way, by running forinstance 2x150 mm (2x6”)tapes, the machine has a totalband width of 300 mm andtherefore its productivity while atthe same time, it can handlecurved surfaces with steeringrequirements that only 150 mm(6”) wide tape can handle, allthat keeping the scrap volumeassociated to the 150 mm (6”)wide tape.

5 Axis Gantry/Column

Routing and Drilling

Machine With Flexible

Tooling System

10 11MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

TORRESMILL®

AND TORRESTOOL®

OPTIONS· Volumetric compensation

system· Temperature controlled

enclosure· Tool management· Automatic calibration

OPTIONS· Laser based vision system· Photogrametry measuring

system· Dry/wet machining· Temperature compensation

The well proven sturdy and, tor-sion free gantry concept enablesthe machine to provide the max-imum acceleration-decelerationat the highest feed rates.

A high frequency spindle provides appropriate spindlerevolutions for optimal cuttingand maximum feed rates.

TORRESMILL® Gantry or ColumnMilling Machines are built in various sizes to meet customerrequirements and specifica-tions.

An in house developed uniquesoftware to offset the effect ofspring back on Composite com-ponents is optionally available.This software takes a number ofpart measuring readings, com-pares the theoretical vs real partshape and corrects the CNC pro-gram accordingly.

By integrating the TORRESTOOL®

with the TORRESMILL® 5 axesHigh Speed Milling Machine,the system provides the highestdegree of flexibility and reduceschanges over time from onework piece configuration toanother to less than 2 minutes.All supports rods with vacuumcups move simultaneously inthe X/Y/Z axes and are auto-matically locked in their finalpositions.

The TORRESMILL® can also bedelivered with a conventional T slotted table for hard toolingset up.

A Vertical TORRESMILL® can alsobe provided eventually workingintegrated with a head Stock/Tail Stock system for mandrelrotation on a fully interpolatedmanner with the TORRESMILL®.

TORRESMILL® 5-axes gantryDNC-CNC high speed millingmachine series has been specially designed for highspeed milling and drilling of aircraft Carbon Fiber structural components. The integration with theTORRESTOOL® provides the maximum flexibility.

Ultrasonic Composite

Cutting Machine

12 13MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

TORRESPANEX

OPTIONS· Automatic roll dispenser· Laser mapping system· Labelling system· Vacuum table· Conveyor table· Nesting Software

OPTIONS· Automatic cutter

orientation system · Cutter braking

detector system

The lightweight, sturdy torsionfree gantry concept enables themachine to provide maximumacceleration-deceleration at thehighest feed rates.

The TORRESPANEX can be built in 2D or 3D configurations.An ultrasonic cutting systemprovides the appropriate highfrequency vibration capabilitiesfor optimal cutting conditionsand maximum feed rates.

The well proven modularmachine system is the basis for each individual application.

The TORRESPANEX 6-axesGantry CNC high speed ultrasonic cutting Machine has been specially designedfor High Speed Cutting of aircraft uncured compositestructural components.

The machine may also include a vacuum table to supportthe component to be cut or a conveyor for easy part loading/unloading can be provided.Nesting software is optionallyavailable to optimize the materi-al usage.

TORRESPANEX Gantry cuttingmachines are built in varioussizes to meet customer require-ments and specifications.

5 Axis Gantry or Column

Drilling and Countersinking

Machine with Flexible

Tooling System

TORRESDRILLAND TORRESTOOL®

14 15MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

OPTIONS· Vision based measuring

system· Pressure foot· Countersink depth control

Wet/dry drilling· Environmental controlled

enclosure

The well proven lightweight,sturdy and, torsion free gantryor column concept enables themachine to provide the maxi-mum acceleration-decelerationat the highest feed rates, delivering the most demandingaccuracy.

A high frequency spindle provides appropriate spindlerevolutions for optimal drillingand countersinking at maximum feed rates.

TORRESDRIL Gantry or columnDrilling Machines are built invarious sizes to meet customerrequirements and can be builtfor milling purposes too.

The TORRESDRILL Automatic Drilling and Countersinking Machine specially designed for highspeed drilling and countersinking Carbon Fibercomponents, as well as stacksof different materials.

A unique pressure foot designprovides an efficient and highlyaccurate solution for counter-sinking Composite componentsas well as to drill and counter-sink a stack of different materi-als (Al, Carbon Fiber, Ti, etc.).

A in house developed uniquesoftware to offset the effect ofspring back on Composite com-ponents is optionally available.This software takes a number of part measuring readings,compares the theoretical vs realpart shape and corrects the CNC

program accordingly.

By integrating the TORRESTOOL®

with the TORRESDRIL, the systemprovides the highest degree offlexibility. All supports rods withvacuum cups or clampingdevices move simultaneously in the X/Y/Z axes and are automatically locked in theirfinal positions.

Multiflexible Universal

Holding Fixture

TORRESTOOL®

16 17MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

OPTIONS· Automatic repositioning

software integrated with TORRESMILL® or TORRESLASER®

· Multipart set up software· Absolute positioning system

OPTIONS· Part automatic searching· Vacuum level control· Special attachments and cups

to fixture complex surface components

The TORRESTOOL® is a modularconcept consisting on a numberof carriages that move on the X-axis direction, with a number of supports per carriage, thatmove on the Y and on the Z axes under a computer programinstructions.

Each support rod has a self-adjusting 45º tilting capabilityvacuum holding cup on the top.In certain applications a partclamping device is set up on topof the rod instead.

The TORRESTOOL® is controlledfrom a PC where all part pro-grams are downloaded from,into the MTORRES developedmultiaxes control system to trig-ger the TORRESTOOL® reposition-ing process.

The TORRESTOOL® is a Multiflexible Universal Holding Fixture speciallydesigned to support in spaceaircraft structural componentswhile they are machined.

All supports rods move simulta-neously in X, Y, Z axes and areautomatically locked in theirfinal position. All motions areservo driven and NC controlled.Ground guide ways, rack andpinion and ball crews systemsare used to drive the axes.

By integrating the TORRESTOOL®

with the TORRESMILL® or TORRESDRIL or TORRESLASER®,the system provides the highestdegree of flexibility on theirmilling, drilling or laser cuttingoperations, reducing changeover time from one part configu-ration to next to a maximum oftwo minutes. All supports rodswith vacuum cups or clampingdevices move simultaneously in the X/Y/Z axes and are automatically locked in theirfinal positions.

TORRESTOOL® Universal HoldingFixtures are available in differentdesign configurations, horizon-tal, vertical, round, 3 Axis, singleaxis, etc, and in any required sizeto be integrated with otherMTORRES machines.

The TORRESTOOL® has a sophisti-cated built in executive softwarepackage (HMI) to allow anextremely easy machine opera-tion, as well as its maintenance,providing self-diagnosis routinesetc.

Applications are machining,assembly, laser scribing, etc.

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING 18 19

Ultrasonic Inspection

Machine

TORRESSONIC

OPTIONS· Automatic cleaning· Automatic defect evaluation· Non contact probing system· Defect marking system· Cartesian Axis machine· Robotic special cell

water suction system

OPTIONS· Automatic end effector

changer· Flexible part holding

(Special TORRESTOOL®)

The TORRESSONIC is a set of accurate, stiff and reliablemechanics, control electronicsand software subsystems, working together to make anadvanced ultrasonic unit to scana part capturing data accordingto a defined strategy.

TORRESSONIC system are alwayscustomized and built on anyarchitecture to fulfil specific customer requirements.

TORRESSONIC provides aframe in which several ultra-sonic scanning applicationscan be implemented, fromwater-jet thru-transmissionequipment to pulse-echo and phased-array systems, forlarge aircraft structural partsNon Destructive Inspection.

MTORRES integrates commer-cially available high added valueinspection systems (end effec-tors, electronics, data acquisitionand evaluation software)built by someone else into theTORRESSONIC solution, whichcan use conventional NDI Tech-nologies, Pulse-Echo and Thru-Transmission, either via water jetor immersion, either singlechannel or multichannel, as wellas Multichannel Phased ArrayTechnology.

5 Axis Crawling

Drilling and Riveting

Machine

Flexible DrillingHead [FDH]

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING 20 21

The FDH is a 5 interpolated axisdrilling machine with modulardesign for easy system cus-tomization.

Its principle is to ‘walk’ over theaircraft fuselage, holding onplace by means of a set of vacu-um cups. Once the FDH ‘walks’to position, gets locked with thevacuum cups and is ready toperform the drilling/rivetingoperation.

After drilling/riveting at the current area, the FDH walks onemore step, by releasing the vacuum at half of the cups andmoving them one step ahead,where it will lock them on placeagain getting ready for the nextdrilling/riveting operation.

FLEXIBLE DRILLING HEAD(FDH) 5 Axis Drilling CrawlerRobot is a portable and auto-nomous drilling and rivetingstandalone robot.

The FDH does not need anyadditional guiding systemmechanically engaged to theAircraft to walk on its fuselage,irrespective of its position, even upside down.

FDH is a 5 axes autonomousplatform that carries the neces-sary end-effectors for drillingand countersinking.

The robot optimal designensures the best drilling andcountersinking positioning accu-racy and a high speed perform-ance at the lowest weight.A vision and laser systemensures that the FDH follows thedesired path and correct CNC

program from theoretical to realpath.

A portable electric cabinet is provided, connected to the FDH

by means of a minimum hosing/wiring harness.

A MTORRES developed controlsystem allows the FDH to workwithout needing a conventionalCNC system.

Applications are drilling and riveting circumferential, longitudinal and conical joints.

A 5 minutes set up on place by 2 operators is enough to beready to start.

22 23MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

Special Projectson Composites

MTORRES is in a unique positionto apply at other industrial sectors using composites, itsextremely wide knowledge and experience on compositemanufacturing systems at theAerospace Industry.

From that stand point, Compos-ite solutions for boat and windmill blades manufacturingprocesses have been successful-ly implemented in the past. As aresult, a number of Racing Boatsand Wind Mill Blades have beenbuilt at MTORRES facilities inrecent years. Additional industri-al sectors, either using or aboutto start using composite materi-als (automotive, construction,etc.) are also in advanced con-versations as potential users ofthe MTORRES technology.

Our Aerospace Industry wellknown solutions can be applied,have been applied and will beapplied to other products manu-facturing processes at otherindustries.

Not only in the case of prepregmaterial processes but ResinInfusion, Dry Material lamina-tion, Thermoplastics lamination,etc are areas in which MTORRES

is currently involved on a num-ber of development projects toimplement new solutions, aswell as to modify and adaptexisting solutions, on an indus-trial manner.

In addition to composite components fabrication otherstages of the process can beaccomplished as well. CurrentMTORRES technology, experienceand powerful engineering capa-bilities allows us to address acomprehensive process solution,from the lamination equipmentto components cutting, machin-ing, inspecting, as well as assem-bling processes.

Summarizing, a total compositemanufacturing solution can beprovided out of a single source.

Automation of those processesare key to reduce cost andincrease productivity, quality,exchangeability and consistencyand MTORRES solutions are perfect to fulfil those goals.

24 25MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING

Software

1. Automatic Tape Layer Programming Software Torlay

TORLAY is a CATIA V5 fully inte-grated application developed by MTORRES to allow the creationof CNC part programs for theTORRESLAYUP in an easy anduser friendly manner. It allowsthe programmer to use all theinitial designs that they have in CATIA V5 without any loss ofinformation due to CAD formattranslations.

The programmer enters a number of parameters into the system to generate the tapetrajectory using base surfaces,ply contours and laying orienta-tions. It facilitates to the user the definition of machine andmaterial constrains (minimumlength, allowed cutting angles,minimum tape with, etc.) to easily obtain a executable CNC

program.

Other laying parameters such as scrap area, flow area, clearsurface, laying feed rates, etccan also be determined from the TORLAY application.

TORLAY displays what the ply will look like based on theparameters that the program-mer entered for him/her todepurate the ply by modifyingthose parameters.

TORLAY includes a built in Post-processor to generate the CNC

program.

2. Automatic Fiber Placement Programming Software Torfiber

As in the Tape Layer Machine,TORFIBER is a CATIA V5 fully inte-grated application developed by MTORRES to allow the cre-ation of CNC part programs forthe TORRESFIBERLAYUP in aneasy and user friendly manner. It allows the programmer to useall the initial part designs thatthey have in CATIA V5 without anyloss of information due to CAD

format translations.

The programmer enters param-eters into the TORFIBER programto complete the ply definition.The system is very comprehen-sive and flexible allowing theprogrammer to take differentlaying strategies.

Again, the system displays theply on the screen for the pro-grammer to analyze and eventu-ally modify some of the parame-ters entered to obtain a fullysatisfactory and machine doableply.

The integrated software allowsthe creation of machine exe-cutable files directly from theDELMIA V5 environment.

TORFIBER application generatesall the laying process informationin the CATPROCESS document, inDELMIA environment. It also post-processes the information in theCATPROCESS document to gener-ate CNC file.

3. Simulation

MTORRES has developed over theyears unique and specific solu-tions for Machine simulation,integrated in DELMIA V5, particu-larly for our Composite Manufac-turing equipment. Our simula-tion soft reads CAD models andNC programs executing them ona virtual machine detecting colli-sions etc. for program correction.

4. HMI

HMI applications are developedto create user friendly packagesto allow the operator to runcomplex NC manufacturingprocesses on an easy and errorsfree mode.

MTORRES HMI’s are customizedfor each application to minimizethe operator training require-ments and time and still allowing an efficient and safeway to run the machine.

MTORRES DISEÑOS

INDUSTRIALES SAU

GetafeMadrid, Spain

MTORRES DISEÑOS

INDUSTRIALES SAU

Torres de ElorzNavarra, Spain

MTORRES

DEUTSCHLAND GMBH

Stade, Germany

US East Coast

UK

USWichita

MTORRES DISEÑOS

INDUSTRIALES SAU

Fuente ÁlamoMurcia, Spain

SitesServices Centers

MTorresWorldwide

MTORRES TOTAL SOLUTION FOR CARBON FIBER MANUFACTURING 26 27

MTorres Sites

MTORRES AMERICA

Bothell WA, USA

US WestCoast Japan

China

SpainNAVARRA

Ctra. Pamplona-Huesca, Km 931119 Torres de ElorzT +34 948 317 811F +34 948 317 952

MURCIA

Ctra. El Estrecho-Lobosillo, Km 230320 Fuente ÁlamoT +34 968 878 400F +34 968 878 420

MADRID

Avda. Rita Levi-Montalcini, 2928906 Getafe MadridT +34 91 683 74 74F +34 91 683 74 75

United States21520, 30th Drive SE, Suite 210Bothell, Wa 98021T +1 425 984 2700F +1 425 984 2735

GermanyWolf-von-Baudissin-Weg 1D-21684 StadeT +49 4141 939 940F +49 4141 939 9429

BrazilR Bakhos Yossef Alwan, 84Sala 3Jardim das IndustriasSao Jose Dos CamposSao PauloT +55 1291 213 117

MTORRES

DO BRASIL

Sao Jose Dos CamposBrazil