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This paper describes work being conducted by OC Robotics and Airbus to develop snake-arm robots to conduct assembly tasks within wing boxes - an area currently inaccessible for automation. The composite, single skin construction of aircraft structures presents new assembly challenges. Currently during box close-out it is necessary for aircraft fitters to climb into the wing box through small access panels and use manual or power tools to perform a variety of tasks. In future wing designs it may be that certain parts of the wing do not provide adequate access for manual assembly methods. It is also known that these manual interventions introduce health and safety concerns with their associated costs. Snake-arm robots provide a means to replace manual procedures by delivering the required tools to all areas of the wing box. Such a development has broader implications for aircraft design and assembly.

This paper describes work being conducted by OC Robotics and Airbus to develop snake-arm robot technology suitable for conducting automated inspection and assembly tasks within wing boxes. The composite, single skin construction of aircraft structures presents new challenges for robotic assembly. During box close-out it is necessary for aircraft fitters to climb into the wing box through a small access panel and use manual or power tools to perform a variety of tasks. These manual interventions give rise to a number of health and safety concerns. Snake-arm robots provide a means to replace manual procedures by delivering the required tools to all areas of the wing box. The advantages of automating in-wing processes will be discussed. This paper presents early stage results of the demonstration snake-arm robot and outlines expectations for future development.

The paper details the two main phases of the research and development process which led to the current state on the stage 0 dedicated to the assembly of the A320 bottom panel on stringers and buttstraps. First phase: evaluation of the feasibility through trials on platform with a serial KUKA robot, evidence to achieve correctly 3/8" diameter and evidence of the difficulties to achieve the performances for the positioning accuracy. Second phase: development of specific solution on calibration and end effector, implementation on site, definitive performance proved during production.