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Traditional solutions developed for the aerospace industry must overcome challenges posed for automation systems like design, requalification, large manual content, restricted access, and tight tolerances. At the same time, automated systems should avoid the use of dedicated equipment so they can be shared between jigs; moved between floor levels and access either side of the workpiece. This article describes the development of a robotic system for drilling and inspection for small aerostructure manufacturing specifically designed to tackle these requirements. The system comprises three work packages: connection within the digital thread (from concept through to operational metrics including Statistical Process Control), innovative lightweight / low energy drill, and auto tool-change with in-process metrology. The validation tests demonstrating Technology Readiness Level 6 are presented and results are shown and discussed.

The 30 month COMET project aims to overcome the challenges facing European manufacturing industries by developing innovative machining systems that are flexible, reliable and predictable with an average of 30% cost efficiency savings in comparison to machine tools. From a conceptual point of view, industrial robot technology could provide an excellent base for machining being both flexible and cost efficient. However, industrial robots lack absolute positioning accuracy, are unable to reject disturbances in terms of process forces and lack reliable programming and simulation tools to ensure right first time machining, once production commences. These three critical limitations currently prevent the use of robots in typical machining applications. The COMET project is co-funded by the European Commission as part of the European Economic Recovery Plan (EERP) adopted in 2008.

The 30 month COMET project aims to overcome the challenges facing European manufacturing industries by developing innovative machining systems that are flexible, reliable and predictable with an average of 30% cost efficiency savings in comparison to machine tools. From a conceptual point of view, industrial robot technology could provide an excellent base for machining being both flexible and cost efficient. However, industrial robots lack absolute positioning accuracy, are unable to reject disturbances in terms of process forces and lack reliable programming and simulation tools to ensure right first time machining, once production commences. These three critical limitations currently prevent the use of robots in typical machining applications. The COMET project is co-funded by the European Commission as part of the European Economic Recovery Plan (EERP) adopted in 2008.

This paper is a neutral standard for testing robotics for usage in large volume applications. This will be followed by an oral presentation on real test results achieved to-date, given via a PowerPoint presentation at SAE Wichita 2010. The "state-of-the-art" in robot testing includes ISO:9283 "Manipulating industrial robots - Performance criteria and related test method." Previous practical work from M ₃ at Airbus UK is also used. These protocols focus on the performance of a robot fixed to the floor. The objective of this paper is to expand upon that work for robots on external axis to provide much larger working volumes as often required in the aerospace industry. This paper focuses on quasi-static applications only (i.e., drilling) covering the following topics: - Test criteria for the robot, - Localization methods to improve performance, - Process time implications from different localization methods.

Complex aircraft components such as blades have a number of production variables that need to be controlled to maximise the production throughput in a factory. These start with variances in forging process and some hidden features needing ultrasonics. This means there is a level of bespoke machining on every part. Traditionally this has been achieved with high level of manual finishing. This paper/presentation is a case study on how metrology has been integrated with robotics to give complex dimension control and maximise automated machining.

Composite parts are difficult to produce, especially the control of the part thickness. This paper/presentation is in two parts, and describes an innovative process using integrated metrology for composite part manufacturing of a generic wing flap. This first paper describes the composite assembly process from a metrology focus and how an integrated Laser Radar system is used to measure actual thickness build-up compared to theoretical CAD/CAM nominal. The second paper is on the automation capability of making the part. A robot is used to apply the composite ply's/tows. To analyze the machines capability and tune performance a high speed photogrammetry system is used. It is also used for automated placement of honeycombed structures within the part build, where guided assembly can be automated in future.

Composite parts are difficult to produce, especially the control of the part thickness. This paper/presentation is in two parts, and describes an innovative process using integrated metrology for composite part manufacturing of a generic wing flap. The first paper describes the composite assembly process from a metrology focus and how an integrated Laser Radar system is used to measure actual thickness build-up compared to theoretical CAD/CAM nominal. This second paper is on the automation capability of making the part. A robot is used to apply the composite ply's/tows. To analyze the machines capability and tune performance a high speed photogrammetry system is used. It is also used for automated placement of honeycombed structures within the part build, where guided assembly can be automated in future.