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the machine are truly impressive: The
peening cabin alone is 13.5 m long, 4.5
m wide and 6.0 m high.
The facility features an injector-gravitation
peening system for shot of 4.00
mm in diameter. It is designed for
forming components with maximum
dimensions of 11,000 x 3,100 x 1,500
mm3 (length x breadth x height) and
can be positioned to an accuracy of ±
0.1 mm for all six robot-axes. The same
conditions are available on both additional
axes for corresponding linear
movement and for the transport wagon
which charges the components.
The Swiss company met all the project
deadlines and delivered the machine
to the Airbus plant in Nordenham
within 1 year. Key factors necessary to
achieve these goals included computer
simulation in conjunction with the German
robot manufacturer Motoman,
simultaneous engineering and regular
project meetings with Airbus and KSA
in order to exchange new information
arising from pre-run production.
Turn-key at Airbus Site
Installation and acceptance tests of the
machine took place in Nordenham in
November 2003, fitting in perfectly
with Airbus planning. The machine
was then programmed by KSA for the
automated peen forming of 8 different
A 380 fuselage shells using online velocity
measurement for machine calibra-
Implementing Automated Shot Peening at Airbus' Site
MFN page 19
Peening MFN page 20 Vol. 5, May Issue
tion as well as a 3-D laser measurement
system for the automated teaching of
peening traces.
A short training session for Airbus
operators followed. Because of the
high degree of automation, no extra
personnel is necessary for the shot
peening machine; the programs are
simply called up by the operators of the
nearby laser-beam welding machine. In
order to ensure high availability of the
machine, Baiker and KSA have also defined
a regular maintenance schedule.
New Component Service
Airbus planning for the introduction
of laser-beam welded fuselage shells
to other aircraft is certainly ambitious:
Besides the A 380 programme, laserbeam
welded panels will be used in
the A 318 and A 340. And the Airbus
single aisle family will follow.
All new technology and machinery
must therefore be designed for high
flexibility. KSA offers a ‘new component
service’, which means carrying out
programming offline and then transferring
the program to the machine in Nordenham.
In this way, a new fuselage
shell for shot peening can be introduced
within an extremely short time and with
a minimum of disruption to serial 3-
shift production at the plant.
Start of a New Era in Shot Peening
The Airbus example can be seen as a
first benchmark for shot peen forming
as a state-of-the-art industrial process,
i.e. a fully automated process which is
integrated in the aircraft manufacturing
chain and requires very little operator
time. Moreover, the peen forming process
automation implemented at Airbus
is completely transferable to all other
shot peening applications. The times of
‘trial and error’ are over.
It is now time to regard shot peening in
a new light: High-precision robot-aided
machines and new process control
technologies raise shot peening to the
level of modern industrial processes.
Standards such as ‘complete process
IN THE SPOT LIGHT:
KSA specializes in shot peening
process automation and offers
one-stop shopping services and
solutions for demanding customers.
For Airbus, the German
company is serving as a general
contractor, implementing automated
shot peening in the form
of contract peening and system
integration services.
Baiker AG in Zurich delivered
the shot peening equipment.
The Swiss company manufactures
CNC and robotic dry &
wet peening machines and
works mainly for the aviation
and automotive industries. It
was founded in 1935.
Author: Axel Friese
Tel. +49.2407.51.565
E-mail: axel.friese@ebv.de
For Information on process control:
KSA GmbH
Weststrasse 24
52074 Aachen, Germany
Tel. +49.241.879795-0
Fax: +49.241.879795-9
E-mail: info@kugelstrahlzentrum.de
www.ksa.de.com
For information on equipment:
Baiker AG
Alpenstrasse 1
8152 Glattbrugg, Switzerland
Tel. +41.43.211 8663
Fax: +41.43.211 6271
E-mail: info@baiker.ch
www.baiker.ch
control and documentation’ and ‘computability’
can now also be applied to
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