The current automation solutions for the assembly of aero-structures are based on large dedicated machines, such as auto-riveters, with the majority of the individual components being manually assembled prior to the riveting process. The high capital cost and long lead times of these machines can lead to capacity bottlenecks and the requirement for significant manual riveting. The design and operation of special purpose end-effectors for assembly and solid riveting and their integration in an aero-structure sub-assembly fabrication cell are described. The robots are controlled by a novel control system which allows the cell to compensate for distortion and misalignment of the components. To prove the assembly process a number of experiments were performed to prove the accuracy and repeatability of the process. A single stringer 300 mm in length was used with three evenly spaced 'part to part' holes. The pairs of holes are used for alignment purposes during manual assembly. The cell has been validated using representative parts and is now being tested using components from the Bombardier CRJ700 regional jet. Test coupons have also been produced and the quality of the installed rivets has been passed for production by Bombardier. The developed cell provides a realistic alternative to the existing large-scale auto-riveters. The key to the success of the system is the combination of non-contact metrology and the cell control system. The system developed also significantly reduces the impact of new health and safety legislation through the reduction in manual handling and riveting. The complete cell is also estimated to cost about 60 per cent less than the current generation of auto-riveting machines. Substantial time savings can also be achieved since the assembly process can be performed concurrently with riveting.
Automated aerostructure assembly
Automatisierte Flugzeugmontage
The Industrial Robot ; 32 , 5 ; 383-387
2005
5 Seiten, 2 Bilder, 1 Tabelle, 8 Quellen
Article (Journal)
English