Enhancing Aerospace Engineering: The Role Of Hexapods In High-Precision Machining

At the International Aerospace Exhibition ILA Berlin 2024, PI unveiled a custom-designed hexapod as part of the LuFo VI-1: ADMAS research project, aimed at improving aircraft construction. This high-performance 6-DOF motion and positioning system (model H-900K101) enhances contour machining for carbon fiber-reinforced composite (CFRP) components, focusing on processes like milling, deburring, sealing, and drilling. The hexapod dynamically compensates for process forces during machining, enabling precise processing while reducing manufacturing times and costs.

Capable of accelerating a 40kg payload in the XY plane at up to 1.2G, the H-900K101 ensures high precision for time-sensitive aerospace applications. Integrated fiber-optic data transmission minimizes latency in the control loop, allowing rapid adjustments for error compensation. Additionally, the project explored condition monitoring through acceleration sensors to detect wear on hexapod struts.

PI’s hexapods offer a compact alternative to traditional serial systems, providing six degrees of freedom with high repeatability and customizable load capacities. This initiative, led by Airbus and supported by the German Federal Ministry for Economic Affairs, culminated in advancements that promise to significantly enhance the efficiency and precision of aerospace manufacturing processes.