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Leica (measuring systems), RTS Advanced
Robotics (robotic technologies) and
Tecnomatix (software and simulation) as well
Airbus UK who project managed the
programme and provided the facilities and
materials.
AWBA demonstrator
Set up in a converted hangar alongside the
main Broughton wing production facility, the
8.5m high AWBA 11 cell demonstrator (Plate
3) is able to build a four-rib wing box section
for Airbus' largest aircraft, the A380, with the
minimum of manual intervention. It
undertakes all the elements needed in the
assembly from the precise handling and
positioning of the 6m high ribs to drilling and
fastening the skins to the ribs. However, it is
not a production cell and cannot build a
complete full-length wing box.
The cell is of a gantry construction that
allows the wing box to be assembled with the
rib vertical, the concept for which was
developed by AMTRI. The upper raft fixed
below the gantry cross member holds the
tooling for the leading edge spar, while tooling
to locate the trailing edge spar is mounted on
the lower raft close to floor level. With the two
spars in position, the first operation is to place
the ribs between the two spars, for which
AMTRI developed the rib carrier robot.
The two spars have a series of pockets to
accept the ribs and the robot has to
manipulate a rib into these two sets of
pockets. To accomplish this, the rail mounted
rib carrier robot has a pivoting axis in addition
to three linear XYZ axes. The sequence is to
take a rib from the store, tilt it at
approximately 458 to the vertical using the
pivot axis, move it into position so that the
bottom edge of the rib locates into the lower
(trailing edge) spar and then bring the rib to
the vertical so that the upper edge locates into
the upper (leading edge) spar. The rib is then
clamped hydraulically.
Locating the rib into the spars requires the
robot to position to an accuracy of ‹0.5mm,
which for such a large structure is precise.
This is accomplished with the aid of the Leica
laser tracker system, which measures the
position, in this case, of the upper and lower
spar tooling and communicates any off-sets to
the robot. The Leica system is used in
industry, particularly in aerospace and
automotive industries, for large-scale, 3D
metrology, and is capable of measuring to
accuracies of ‹0.05mm over distances of up
to 35m. The unit's motorised head directs the
laser beam over a 3D volume up to 70m
diameter to locate and measure the 3D coordinates
of target reflectors placed at the
measurement positions. In the case of the
AWBA demonstrator, the transmitting unit is
located on one of the gantry legs but it is also
portable.
Skin wrapping
After fixing a set of ribs in position, the next
operation is skin wrapping, which was also the
responsibility of AMTRI. Skins are taken
from the store and simultaneously placed
against pads on both sides of the ribs either
Plate 3 The gantry-style AWBA 11 demonstrator set up in a hangar
alongside Airbus UK's wing manufacturing facility at Broughton
299
Automatic wing box assembly developments
Brian Rooks
Industrial Robot: An International Journal
Volume 28 . Number 4 . 2001 . 297±301
two or four at a time and then clamped by a
series of programmable pneumatic clamps.
Working from both sides balances the load
when the clamps are applied and avoids
having to construct a highly stiff supporting
structure. The skin sets cover the trailing
(lower) and leading (upper) part of the wing
box, leaving the centre section open to allow
access for internal fastening, and in
production for manual assembly and
inspection.
Fastening of the skins to the ribs in the
demonstrator involves both external (to the
wing box) and internal operations, for which
two separate robot systems were developed.
The external work of drilling the hole and
inserting the fastener is done with a standard
Kuka K350 six-axis robot rail mounted
(seventh axis) and equipped with a
sophisticated end-effector developed by BAE
Systems ATC. The end-effector incorporates
a vision sensor, high-speed spindle drilling
head and stud inserter (Plate 4).
Before skin wrapping takes place, the robot
uses the vision sensor, which consists of two
cameras and four laser ranger finders, to
locate the 3D position of each pad on the rib.
This is memorised so that after the skin has
been placed the Kuka robot knows exactly
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