Robinson Helicopter

Robinson Helicopters: Flying High with OMAX

It was the mid-1970s.  A mechanical engineer named Frank Robinson decided to build his dream: a small, low-cost helicopter, simple in design and reliable in its function.  Thirty years later, Robinson Helicopter Company is the world's leading manufacturer of civil helicopters, and OMAX technology helps keep Robinson flying high.

"Our OMAX machines have really helped us expand production yet minimize out-sourcing” says Paul Johnson.  As head of Robinson Helicopter Company Tooling Department, Paul has watched Robinson production numbers almost double in three years, climbing from 422 helicopters in 2004 to 823 in 2007.  Currently, about 20 helicopters a week are machined, assembled, tested, and ready for flight. 

“I"m not sure we could meet those numbers using our old system, without our waterjets,” Paul notes.  “An average job of a hundred parts took a couple of days on our CNCs.  On our OMAX machines, that same job takes a couple hours.”  Primarily used to cut sheet metal for hulls, the OMAX machines are cutting more and more production parts, as well as tools and jig sets for the machining of Robinson’s hot-selling helicopters.

Robinson Helicopter Company bought its first OMAX JetMachining® Center in 2004, just as production began to rocket.  It was a 55100 -- with a camera viewer and a custom, 2-foot extension -- purchased to cut sheet metal.  Although Paul Johnson had eyed waterjet systems for several years, it wasn’t until the advent of the Tilt-A-Jet® that he made his move toward OMAX. 

“In the beginning, we hand-cut sheet metal, one sheet at a time.  Then, we used CNCs.”  That sped things up, Paul says, since the sheets could be stacked to 250-thousands of an inch.  But the OMAX made cutting even faster.  “With the Tilt-A-Jet, we can cut multiple sheets, stacked to a thickness of 400-thousandths of an inch, and do it within tolerances.”

That first 55100 is now joined by three more OMAX machining centers: another 55100, an 80160, and a 5555.  Paul sees additional OMAX machines in Robinson’s future.  “When we got that 5555, my manager said, 'This is the perfect size.  We should have gotten two of these.’  So we’ll probably get another one real soon.”

Most of the cutting is done with standard-sized nozzles, but - for more intricate cuts –Robinson purchased one MiniJet.  All of the OMAX machines are equipped with P3050V pumps.  They also have closed-loop water recovery systems; chillers, and sludge removal systems, options that lower operating costs and keep run-times high. 

Each of the machines operates 11 hours a day cutting helicopter hulls and parts, plus tools, fixtures, and jigs for use on the production line.  Paul Johnson says he continually finds new ways to save money and time by using an OMAX abrasivejet instead of a CNC.  For instance, until recently, the jig set used to bond helicopter rotor blades was cut on a CNC, a process that took a week.  Aluminum was used because it’s easy to machine, but that same machineability gave the jig set a short life span.  Enter the OMAX.  Because OMAX abrasivejets easily cut the toughest materials, the jig set is now made out of more durable stainless steel.  Each jig set lasts longer and – instead of a week – a new jig can be cut in one afternoon. 

In spite of their heavy use, Paul says Robinson Helicopter Company has only just begun to tap the capabilities of the OMAX systems.  There are currently 1400 cutting profiles stored in the Intelli-MAX® software, with more being added everyday.  Older blueprints and scans are constantly being converted to CAD files, using Intelli-MAX.  “The software is wonderful,” says Paul.  “Anybody can learn it in half a day.  It was a big selling point.”

OMAX software flexibility and ease-of-use is playing a central role in Robinson’s current helicopter R & D.  On the drawing board is a new, 5-seat model that will join Robinson’s best-selling 2-seat and 4-seat helicopters.  When developing these earlier models, templates for parts were hand-made.  Any changes in design often meant days of additional work.  Now, as engineers design, test, then re-design parts for the new helicopter prototype, OMAX makes it easy.  An hour after getting new specifications, Paul and his crew are in production; within the day, they can deliver re-designed parts to the engineers. 

“OMAX has been a life-saver,” Paul explains.  “Between R & D and our production rates, we just couldn’t have done it without OMAX.”

Robinson Helicopter Company
President and Chairman: Frank Robinson
Location: Torrance, CA
Specializes in: Civil aviation helicopters
Founded: 1973
Website: www.robinsonheli.com