Electroimpact perfectsAFP systems
High precision and dynamics for automated manufacturing processes in the aviation industry
A lot of movement in automated fiber placement technology
Electroimpact is one of the world's leading providers of automated manufacturing solutions for the aerospace industry. The company is setting new standards in the field of automated fiber placement (AFP) with highly complex systems for customers such as Boeing, Airbus, and NASA. A milestone was reached in 2016 with the integration of WITTENSTEIN's Galaxie® drive system, which significantly increased the precision, dynamics, and efficiency of AFP technology.
Innovative AFP technology for the aerospace industry
Working closely with Electroimpact, WITTENSTEIN has developed a revolutionary AFP machine design featuring the high-precision Galaxie® gearbox. The result: significantly increased productivity, minimized machine stress, and maximum positioning accuracy. These advances enable the production of large aircraft components – such as spars and wing skins – in one piece.
Thanks to state-of-the-art contouring capabilities and backlash-free drive technology with a hydrodynamic lubricating film, aerodynamically optimized wings can now be manufactured more efficiently. The compact design also allows for flexible motion control on the rotary axes.
Another highlight: the new AFP system reduces the manufacturing process for wing spars up to 33.5 meters in length from three to just one step. A modular, high-precision laying head in a mobile gantry construction applies several hundred layers of carbon fiber-reinforced material with precision – including automatic rotation and swivel movement of ±90° to produce complex U-shapes in a single pass.
The performance of these machines marks a quantum leap forward from our previous work. The great thing about it is that we have to demand less from the process to achieve this result.
Technology highlight: Servo creel heads as the next milestone
Following the success of the dynamic AFP machines, Electroimpact and WITTENSTEIN have achieved another leap in innovation with the development of servo creel heads. The aim was to match the performance of the modular laying head to the high level of the machine.
Instead of a central motor with coil brakes, each individual coil now has its own drive, enabling precise rotation control. At the heart of this solution are 16 compact TP+ gearboxes from WITTENSTEIN per head – selected for their exceptional rigidity, efficiency, and torque density.
The result: maximum synchronisation between the machine and the laying head, significantly faster and higher-quality layups – a real game changer in AFP technology.
Our products in use at Electroimpact
Galaxie® GH
With the WITTENSTEIN Galaxie® system, Electroimpact achieved a quantum leap in terms of performance, scope, and precision of AFP technology.
Galaxie® D
Hollow shaft compact drive with the typical characteristics of a gearbox: high torque density, torsional rigidity, positioning accuracy, and zero backlash, with a compact integrated synchronous motor.
TP+
The smallest version in the TP+ gearbox series, with its combination of superior rigidity, efficiency, torque density, compact design, and low mass, forms the heart of the servo creel head system.