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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.

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.