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This paper describes and demonstrates the use of an assembly centric design algorithm as an aid to achieving minimal hard tooling assembly concepts. The algorithm consists of a number of logically ordered design methodologies and also aids the identification of other enabling technologies. Included in the methodologies is an innovative systems analysis tool that enables the comparison of alternative assembly concepts, and the prediction and control of the total assembly error, at the outline stage of the design.

The paper details two phases of work completed by Airbus UK to create a standard deployment platform for robotic processes. The initial part of the paper focuses on an aerospace capability study developed to benchmark a number of robot models. The tests define absolute accuracies within full and restricted work envelopes, static and dynamic flexure, and temperature effects on the robot manipulator. The second part of the paper describes the development of an adaptive control process to accurately position singular or co-operating robots within a large working envelope. The solution is not dependent on complex software algorithms within the robot controller or restrictive laser metrology interfaces. The paper illustrates how a number of standard industrial products can be ‘fused together’ to provide a robust industrial solution.