Thanks to laser projectors several teams can work on the same project simultaneously and independently

Workflow optimization in the manufacture of rotor blades - Multi-tasking feature speeds up complex work sequences

In the manufacture of glass fibre rotors the process of positioning the prepregs can be markedly accelerated by the use of laser projectors. The innovative multi-tasking feature of LAP’s CAD-PRO laser projectors supports teams working on one and the same wing in performing different activities simultaneously and independently of each other. This optimizes the workflow, especially during the manufacture of large components.

LAP CAD-PRO 3D laser projectors find their use in the manufacture of rotor blades for positioning the glass fibre prepregs with an accuracy of a millimetre. They project the contours of the
to-be-positioned mats and built-in parts onto the curved surfaces of the casting mould with utmost precision. In so doing they indicate not only the positions of the fibre mats but also where flanges, webs, profiles and receptors have to go. This eliminates the time-consuming procedure of manual contour measurements and the handling of templates.

For rotor blades up to a length of 65 meters, LAP offers the multi-head system, i.e. several projectors with overlapping ranges cover the complete length of the wings. Thanks to their operating accuracy in the millimeter range and the high reproducibility, the projectors guarantee exact placement of all parts in the desired position.

With the multi-tasking software it is possible to project specifically that contour onto the work surface which each individual team needs for its current job. All teams work independently of each other. This is how the system optimizes workflows and accelerates production.

Colour makes for high safety

LAP is the only manufacturer of laser projectors capable of projecting three colours (green/red/yellow) at the same time. Through this feature it is possible to highlight areas requiring special attention. By changing the colour of the complete contour from red to yellow or green, the system can also indicate the work status, i.e. which parts have to be taken care of next, which jobs are in progress and which have already been completed. For optimal visibility of the contour, always that colour which reflects best on the colour of the base material can be selected.

A contour is projected onto a surface by means of a laser beam deflected by two rotary, electrically actuated mirrors (galvanometers). This takes place at such a high speed that the human eye sees the contour as a continuous line. At a distance of four meters above the working surface the laser projectors achieve a projection accuracy of +/- 0.5 mm.

The projectors are usually mounted underneath the workshop ceiling or on a special supporting structure. The LAP laser heads are hermetically sealed in order to prevent dirt – for example, dust - from entering. Variations in ambient temperature are compensated by an active thermoelectric air conditioning system. This solution guarantees a long service life of the laser modules. Thanks to their compact and light-weight design, the systems can be conveniently integrated into existing production plants.

The LAP PRO-SOFT 3D software controls the complete work sequence from the input of CAD data all the way through to the transmission of control data to the projectors and the sequence of individual work steps. Additionally it guides the operator step by step through the entire process of component build-up.

LAP is the only manufacturer using digital controllers for setting the mirrors. This avoids any internal, system-specific drift. The projectors distinguish themselves by high accuracy of repetition and stability of projection. What is more, the use of digital technology makes the signal transmission to the electronic control system extremely secure.

At freely selectable time intervals the system automatically checks the position of several reference points on the working surface, guaranteeing exact system calibration (target check function). Additional automatic functions prevent operating errors and ensure that the system operates at all times with highest precision and reproducibility.

About LAP

For 25 years LAP has supplied laser-based systems for high-precision projection of geometric dimensions in industrial and medical applications. LAP systems excel at providing ultra-precise measurement results under harshest operating conditions. Hundreds of LAP systems are tried and tested every day in extremely challenging production environments.

Among the customers of the company, which today employs more than 150 people, are leading companies such as Airbus, Boeing, Philips, Siemens, BMW and ThyssenKrupp Steel.

The LAP staff takes care of the company’s worldwide customers from the headquarters in Lüneburg/Germany and through an international network of branches and technical agencies.
LAP Laser GmbH
Axel Rieckmann, Sales Manager Industrial Systems

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