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forces either through the delivery structure (the robot) or
through the aircraft structure. The latter is the preferred
option for snake-arm robots, since this type of robot will
tend to be less rigid than an industrial robot. However
this approach has strong benefits for industrial robots
too.
DISCUSSION
The prototype has been designed to complete only the
specific processes that were identified by Airbus UK as
being relevant to the manufacture of future aircraft.
However, a snake-arm robot is a method of delivering
any tool or sensor package into restricted access sites.
As such, it is expected that these robots will be used for
in-service inspection and potentially repair as well as
production. The work on field capable snake-arms for
security applications indicates that snake-arm robots are
suitable for field use. In particular the actuators that drive
the arm are all at the base of the arm and the arm itself
is of constant diameter which leads to simple sealing.
Snake-arms can be used as stand-alone systems or in
cooperation with industrial robot. As a standalone
system a snake-arm robot is a steerable borescope.
Independent research is continuing on diameter
reduction which would allow a snake-arm to be used for
engine inspection and repair.
Other tasks that could be considered for aircraft
manufacture include: deburring; drilling; extraction of
foreign bodies; installation of components; insertion of
wire looms; laser welding; leak detection; non
destructive testing; nut-running; painting; removal of
liquids, gases or particulate matter; removal of swarf;
and thermal imaging.
The detailed design of specific snake-arm robots that
have the required performance to achieve each of these
tasks will vary. In general, the detailed design is affected
by the size and mass of the payload; any dynamic loads
transmitted through the arm and the desired response to
such dynamic loads; and the repeatability/accuracy with
which the package needs to be delivered.
There are also constraints on the size and mass of tools.
As a rule of thumb, the tool should be of the same
diameter as the arm itself and only 1.5 times the
diameter in length. This 1:1.5 rule tends to produce a
tool of the correct payload mass for the size of arm and
of a size that can be manipulated. A larger diameter tool
tends to indicate that a larger diameter arm is also
possible. A longer tool becomes increasingly
cumbersome to manipulate and starts to negate the
flexibility of the snake-arm.
The combined effects of the parameters that define the
response to the variety of loading conditions result in a
specification for the required arm stiffness. But, unlike
standard robots, the stiffest arm is not necessarily the
‘best’ solution. A compliant arm has many benefits when
collisions are unavoidable or where a robot arm is
working unguarded alongside a person. Contact with the
environment can be gentle, rather than catastrophic.
Compliance is also useful to attenuate the effects of
large impulses.
Snake-arm robots enable different approaches to be
considered. In the long term such technology may
provide aircraft designers the option to consider
structures that cannot be built with existing manual
methods.
CONCLUSIONS
This paper has described research being conducted by
OC Robotics and Airbus to develop robot technology
suitable for the aerospace industry. The focus of this
paper has been the development of snake-arm robots to
conduct automated inspection and assembly tasks
within rib bays.
The removal of the need for specialist fitters to conduct a
range of tasks within rib bays has many advantages for
the aerospace industry. In particular rib bays have
severe access restrictions and are very confined spaces
in which to work. There are also areas of the wing which
are in practice extremely difficult to reach using manual
methods. In addition, drilling of composites gives rise to
fine dust which, along with use of solvents and noisy
equipment in confined spaces, has the potential for
significant health and safety issues.
These drivers, along with the unrelenting pressure to
increase productivity by standardising aircraft
production, make the development of new automation
solutions for the aerospace sector critical for future
aircraft production. In addition, if aircraft are produced
using advanced automation, it is likely that new tools will
also be required for maintenance and repair operations.
More widely the development of snake-arm robots could
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