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Serial link articulated robots applied in aerospace assembly have largely been limited in scope by deficiencies in positional accuracy. The majority of aerospace applications require tolerances of +/−0.25mm or less which have historically been far beyond reach of the conventional off-the-shelf robot. The recent development of the accurate robot technology represents a paradigm shift for the use of articulated robotics in airframe assembly. With the addition of secondary feedback, high-order kinematic model, and a fully integrated conventional CNC control, robotic technology can now compete on a performance level with customized high precision motion platforms. As a result, the articulated arm can be applied to a much broader range of assembly applications that were once limited to custom machines, including one-up assembly, two-sided drilling and fastening, material removal, and automated fiber placement.

Low rate initial production of the 777X flight control surfaces and wing edges has been underway at the Boeing St. Louis site since early 2017. Drilling, inspection, and temporary fastening tasks are performed by automated multi-function robotic systems supplied by Electroimpact. On the heels of the successful implementation of the initial four (4) systems, Phases II and III are underway to meet increasing production demands with three (3) and four (4) new cells coming online, respectively. Assemblies are dedicated to particular cells for higher-rate production, while all systems are designed for commonality offering strategic backup capability. Safe operation and equipment density are optimized through the use of electronic safeguards. New time-saving process capabilities allow for one-up drilling, hole inspection, fastening, fastener inspection, and stem shaving.