Search Results

In today's aircraft assembly process several new features make drilling operations very challenging according to production requirements. Parts are made of thin or thick multi-material stacks with a large scope to cover and complex assembly sequences. In addition, the current ramp-up in aircraft programs involves to improve productivity while keeping process quality and reliability. In this context robotic solution meets perfectly all these requirements as it is flexible, reconfigurable, fast and agile. Among the possible end-effectors, the Barrel Multi-Function End Effector (BMFEE) appears to be the most flexible solution to allow many different process configurations. The latest developments have been focused on the drilling equipment of this BMFEE. In fact the drilling process efficiency can be constantly improved especially in terms of reliability, quality and productivity. Therefore vibration-assisted drilling system has been integrated into the BMFEE drilling module.

Alema Automation is a company which has a long experience with single robots solutions working in cooperation with an operator for drilling and filling fasteners in aerospace. Based on that experience, we have developed full automation solutions involving 2 robots working in cooperation. These robots are able to manage clamping force on flexible assemblies to avoid burrs, delamination and, in addition, to install 2 sides fasteners. So far industrial robot controllers for cooperating robots have been based on 2 separate controllers requiring specific software from the robotic integrator in order to control the cooperation between robots. Today a key cooperative feature is included in the package delivered by the robot supplier. Thus, it avoids complex programming from the integrator and specific development for cooperation to get more efficient application and also improvement on cycle time.

Looking at ways to improve assembly techniques and cut lead times for serial and future programs, Airbus' research and technology team launched a project some years ago to evaluate greater automation of sub-components or final assembly lines. The idea was to develop a new type of machine or ‘robot’ that could be attached to fuselage sections using suction cups, and walk along it while drilling and installing fasteners. A camera inside the robot takes a snapshot to work out its position on the part, so that it knows where to drill or install what. Once a fixed working area is complete, the robot moves itself into a new position and starts the process again until the whole surface is covered. Three companies - Alema, MTorres and Serra - were approached to develop prototype robots along the same basic principles, although each was asked to follow a slightly different specification to test a range of options, such as weight, size and positioning.

The paper details the two main phases of the research and development process which led to the current state on the stage 0 dedicated to the assembly of the A320 bottom panel on stringers and buttstraps. First phase: evaluation of the feasibility through trials on platform with a serial KUKA robot, evidence to achieve correctly 3/8" diameter and evidence of the difficulties to achieve the performances for the positioning accuracy. Second phase: development of specific solution on calibration and end effector, implementation on site, definitive performance proved during production.