Automating Aerospace valve alignment for scalable production
Business challenge
Product Innovation
Process Innovation
Sector
Aerospace
Technology or capability
Materials Engineering
Automation & Robotics
As part of the Convergence programme, which drives innovation in aerospace manufacturing, Moog faced a critical challenge: scaling production without compromising precision. MTC partnered with Moog to design an innovative automated alignment system that transforms a skilled manual process into a streamlined, future-ready solution.
The challenge presented by Moog to position their valve assemblies has proven a great opportunity to develop a highly-accurate solution using off-the-shelf equipment able to be retro-fitted to a range of test rigs at their facility.
Agata Suwala, Technology Manager, MTC
The Challenge
The ambition to scale production was being hampered by a number of challenges:
- Manual alignment was time-intensive and heavily reliant on artisan skills.
- Existing processes lacked scalability and predictability.
- Moog needed a bolt-on solution to retrofit existing equipment and minimise risk.
MTC's Solution
MTC conducted a comprehensive analysis of Moog’s manual process, followed by a state-of-the-art review to identify automation opportunities. The result was a precision alignment machine capable of positioning assemblies under load with sub-50-micron accuracy. Designed for flexibility, the system integrates seamlessly with existing rigs and adapts to product variations.
- Key features include:
- Reconfigurable sides to accommodate different end effectors and actuation methods.
- A machine controller that co-ordinates with existing equipment and operators.
- Real-time sensor feedback for precision pressing operations.
The Outcome
The project delivered a functional proof-of-concept automated solution (TRL4), backed by rigorous testing and industry expertise. Moog gained confidence in scalability and future production capability, ensuring readiness for anticipated growth.
The MTC team was integral to the success of the Convergence automation projects. Their experience managing innovative projects is considerable. They provided an array of methods and tools, backed up with a broad range of technical knowledge, to capture requirements, promote idea generation, and assess solution concepts. They also have excellent access to industry expertise via their consortium network and substantial experience working alongside technology manufacturers and system integrators.
Dave Bullows and Jeff Scorer, Moog
Benefits to the Client
- De-risked transition from manual to automated processes
- Increased production capacity and scalability
- Reduced reliance on tacit skills, freeing operators for higher-value tasks
Real-time feedback for improved quality control
Up to 10x improvement in operator effectiveness through precision automation
