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Aircraft production is facing various technical challenges, such as large product dimensions, complex joining processes, and organization of assembly tasks. Overcoming such challenges, as well as maintaining low tolerances and small batch sizes, is often difficult to achieve whilst retaining economic viability. ZeMA believes that a semi-automated approach is the most effective way to optimize aircraft section assembly. This can be achieved with a semi-automated riveting process for solid rivets, using Human-Robot-Collaboration in combination with an intuitive Human-Machine-Interaction operating concept. In the assembly of aircraft structures - in this scenario the aircraft aft section - the pressure bulk head is mounted to the section barrel. Two operators work collaboratively in uncomfortable, non-ergonomic positions, yet of course have to maintain exacting quality standards.

Large aircraft sizes with high precision requirements combined with complex joining tasks are typical challenges for aircraft production. To increase competitiveness and effectiveness, the automation of such production processes seems a viable solution for companies in the aircraft sector. When implementing automation, in order to handle small batch sizes and high variation while adhering to tight tolerances, the production equipment must meet high quality standards and flexibility requirements. To achieve the objectives above, tolerance management is essential: deviations are acceptable within limits, as long as they do not result in quality losses and expensive rework. For these reasons, all the interactions between the product, production process and production equipment used must be analyzed in detail. The importance of this analysis is evident in assembly where new technologies are used, such as (semi-)automation using Human-Robot-Collaboration.