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where to drill through the skin and the pad in
one operation. Each hole four per pad is
drilled and deburred and then a stud inserted
in a cycle time of 15 seconds per hole. During
these operations the robot's six axes are
locked in position; in effect the robot is merely
an ``end-effector positioner''. Responsibility
for the drilling technology for these operations
rested with AEA technology. It undertook
tests to establish the optimum drilling
parameters and cutting conditions to ensure
maximum hole quality and minimum burr
size. It also carried out modal analysis and
vibration trials on the robot to study the effect
of these factors on hole accuracy when drilling
automatically.
Swaging of the fastening collar to the stud
inserted during the latter operation is done by
the internal robot, which was developed by
RTS Advanced Robotics (formerly UK
Robotics). Because of the restricted opening
into the wing box ± approximately 1 6 1.5m
± and the 5.5m reach to access the back of the
fastener through the far side skin, RTS could
not apply a standard, off-the-shelf robot and
had to develop a ``special''.
Deployment robot
The finished device is a 10 degrees-of-freedom
robot with a reach of 6.5m. It is made up of the
deployment robot, a telescopic boom that
swivels about a horizontal axis and is mounted
on a linear track to allow access to the full
length of the wing box, and a standard Fanuc
six-axis parallel leg robot. The latter is fitted to
the end of the boom arm and basically acts as
its end effector. The ultimate tooling
consisting of the swaging unit with collar feed
and stereoscopic vision sensor (developed by
BAE Systems ATC) is mounted on the end of
the legged robot. The sensor guides the robot
to find the stud end so that the tooling may
dock with the stud. The collar then slides over
the stud and is pulled tight before it is swaged
onto the stud.
The internal robot is designed to behave
like any other industrial robot, with the
exception that positioning for set-up and
programming is done by a teleoperator-type
strategy. This is to avoid placing an operator
or programmer in a potentially unsafe
position within the confines of a wing box and
also to overcome the problem of a large and
heavy robot arm in a remote position. Using
the teleoperator system, the end effector is
positioned remotely using television cameras
that form part of the tooling, to observe
movement. As a further safety measure, the
Plate 4 External robot consisting of Kuka industrial robot equipped with
special tooling for locating rib pads, drilling and stud insertion
300
Automatic wing box assembly developments
Brian Rooks
Industrial Robot: An International Journal
Volume 28 . Number 4 . 2001 . 297±301
robot arm is fitted with capacitance sensors
to detect the onset of a collision, whether
during teleoperational set-up or automatic
operation.
Throughout the second phase of the AWBA
project, extensive use has been made of
software planning and simulation tools, for
which Tecnomatix provided the solutions
with its eMPower software products. RTS
Advanced Robotics used these robotic
simulation and off-line programming tools
routinely for design of the internal robot, and
BAE Systems ATC used them in the design of
the external drilling and fastening robot. The
whole cell was simulated in 3D to help the
partners understand the interactions of the
various sub-systems and to provide a visual
tool for developing the optimum sequence of
operations. It was also useful in supporting
line-of-light studies during development of
the laser tracking measurement system.
At the later stages of the project a final
model of the whole cell was produced that
enabled the cell's entire build process to be
viewed in 15 minutes, which in ``real life''
would have taken one-and-a-half days.
Subsequently, the simulation model was
scaled-up to the assembly of a full production
wing box, allowing its physical feasibility to be
assessed, the operational sequences and cycle
times to be established and the likely cost of a
full-scale production facility to be estimated.
Airbus UK states that the test work carried
out in the cell has met all expectations and has
already proved the concept of automatic wing
skin panel wrapping. It is capable of handling
and positioning a 6m high wing rib quickly
and safely. It will continue to use the cell to
assess the ``scale-up'' implications as well as
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