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This paper describes the current state of development of a highly flexible assembly and auto-riveting system based around multiple robots and compact and innovative riveting and assembly end-effectors. The riveting end-effectors are capable of drilling, countersinking, sealing and upsetting operations. The assembly end-effectors are re-configurable and can handle ant stringer or frame on a Bombardier Aerospace CRJ700 fuselage panel. The cell is also equipped with non-contact metrology systems that are used to compensate for compliance and remove the requirement for large and complex fixtures. The riveting system has been fully evaluated and a number of test coupons submitted for testing. Detailed analysis of these has proved that the resulting riveted joints are of production quality. The final system will be non-product specific allowing a single cell to produce a number of different aircraft components.

The use of simulation is a recognised part of the design process for automated systems and this has been particularly so in the development of the very large machines used in aero-structure manufacture. As part of an ongoing research project at the University of Nottingham a flexible rapid assembly cell is currently being developed that will be capable of manufacturing a number of different aero-structure sub-assemblies. The individual technologies required such as riveting, drilling and assembly have been developed and the complete cell is now being realised. A key enabler for the realisation of the cell has been the use of simulation, both in the development stage and as a central component of the operating and programming systems. This paper will describe the application of simulation techniques within the cell and during its design.

This paper describes the final development and testing of a combined riveting and assembly cell for the manufacture of Regional Jet Fuselage panels. The cell consists of three industrial robots, two are used for riveting whilst the third is used for stringer placement. The cell has been tested using both simplified test parts and real airframe components. The paper describes the development and testing of the cell along with the enabling technologies that have been implemented to realise the cell.