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KL 504

3D Robot unit with portal
Auto / CarFlugzeug / Airplane

The constantly growing innovative textiles market specifically affects the fiber composites-segment. Here fibers made from carbon, glass, Kevlar® or natural fibers are processed to make particularly light-weight components that are subject to high levels of stress. Both known sewing and special one-side application methods are being used here. Counting on more than 50 years of experience in the field of technical textiles, KSL has developed functional heads which when combined with robotic systems allow 3D-processing. KSL’s specialty is the development and construction of special sewing heads in combination with the synchronization of the robot movement with the sewing drive.

The KL 504 is a robot unit with portal. In addition to one-side sewing heads, lockstitch or 2-thread chain stitch machine technology can also be integrated into this systems. The integration of ultrasonic cutting heads for dry fabrics or prepreg-materials as well as functional heads for measuring and handling jobs are established. Laying heads and Z-pinning heads were developed to precisely introduce or apply reinforcements. The systems are future-oriented and equipped with tool changers so a subsequent extension is possible at any time. The KL 504 is used by large aircraft OEM´s in Europe, Asia and America.



  • 6-axis industrial robot
  • 6  - 210 kg max. playload capacity
  • 900 - 3100 mm max. range of robot arm
  • Robot with portal
  • Additional positioning unit in x- and y- direction
  • Thus much greater range (e.g. x = 6000 mm, y = 3500 mm)
  • Tool changing system


  • Portable user programming interface with touch-screen, 8,4”
  • 6D- mouse for exact positioning of the robot axis
  • USB-Port for simple saving and loading of programs and configuration
  • Hot-pluggable
  • High screen resolution
  • Low weight


  • Multicore Technology
  • Control of 8 independent robot axes,
  • HDD, SSD optional
  • CD- ROM drive, USB, EtherNet
  • Peripheral interfaces: PROFINET, EtherNet/IP, PROFIBUS, DeviceNet, EtherCAT, Interbus


  • Communication software KUKA.PLC ProConOs
  • Extended control


  • Techware software package: GripperTech, UserTech, ExpertTech

Function heads // Single side sewing technologies

RS 512 - Blind stitch: One thread chain stitch
The blindstitch seam is formed with only one single needle thread, which is brought into the material by one curved needle from the top side of the material. The blindstitch head connects virtually all composites from profile or stringer to complex 3D-parts.

RS 530 - 2-needle: One thread chain stitch
A single thread chain stitch seam is formed with only one single needle thread, which is brought into the material by one needle and pulled up by a second to the top side of the material. The two needle head connects virtually all composites such as profile or stringer, even complex 3D-parts.

RS 522 - Tufting: z-reinforcement
The tufting head is forming a seam with a single thread method by one needle. This needle penetrates the material and inserts the thread forming a loop at the lower end of the needle position. The loop can be placed within or outside the material. Tufting is working virtually with all composite components, such as profile, stringer or 3D-parts.

Function heads // Ultrasonic welding, tapelaying, z-pinning

RC 590 - Ultrasonic-cutting
Ultrasonic cutting is used to generate a precise cut with clean edges. Cutting is done without any presurre on the material. Process times are extremly short and energy consumption is low. The ultrasonic cutting head cuts virtually all composites. A quick and efficient solution for parts such as profiles stringer, beams or even complex 3D-parts.

RFP 582 - Tapelaying
To locally reinforce as well as to deposite tapes for medium to small size components with a complex structure, the KSL-tapelaying-head places binder-impregnated or thermoplastic tapes in a tool. The orienatation of the tapes is adjustable by the robot.

RP 591 - Z-Pinning
The Z-pinning head inserts small poles into sandwich parts by using ultrasonic excitation. The poles strengthen the part in z-direction.

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