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The purpose of this paper is to investigate the use of a laser tracker, a laser interferometer system and a telescopic ballbar for assessing the positioning performance of a six‐axis industrial serial robot. The paper also aims to illustrate the limitations of these three metrology instruments for the assessment of robot positioning performance and to demonstrate the inadequacy of simplistic performance tests.

Specific test methods in the case of the laser interferometer system and the telescopic ballbar are proposed. Measurements are analyzed in accordance to the ISO 9283 norm.

It is found that, in static conditions and after a relatively short warm‐up, the unidirectional position repeatability of the non‐calibrated industrial robot under study (an ABB IRB 1600) is better than 37 μm, the unidirectional orientation repeatability is at worst 87 μrad, the linear position accuracy is better than 650 μm, and the rotation accuracy is at worst 2.8 mrad (mainly because of the sixth robot axis). It was also found that the dynamic (radial) errors due to vibrations can be up to approximately ±250 μm along a small circular path at TCP speed of 700 mm/s.

It is pointed out that the use of a laser tracker (or any other large range portable 3D measurement system) is questionable for assessing – let alone analyzing in depth – the unidirectional position repeatability of some of today's industrial robots. It is also demonstrated that the laser interferometer system can be used for measuring linear errors along a linear path of motion as well as angular errors about axes orthogonal to the path of motion. Finally, it is shown that the telescopic ballbar is an excellent, comparably low‐cost, high‐precision tool for assessing the static and dynamic positioning performance of industrial robots and its use in robotics should be further developed.

This work is the first to detail the use of three metrology equipments for assessing the positioning performance of an industrial robot. Experimental results are presented and discussed. Some guidelines for optimizing the positioning performance of an industrial robot are provided.

The purpose of this paper is to increase the measurement accuracy of assembly deviations of an inertial navigation system, a new evaluation and optimal method of assembly metrology system is proposed, which takes into account the uncertainty from laser tracker hardware and coordinate system transformation, and is based on the Monte Carlo method.

The uncertainty model of the laser tracker is established and its parameters are obtained from the known repeated test data by kriging interpolation and the least squares method. The errors of coordinate transformation are reduced by using a weighted point matching method, and the uncertainty of the transformation parameters is obtained based on the generalized inverse theory. The weighting coefficients of each reference point are optimized by the particle swarm optimization method according to the assembly requirements.

The experiment results show that measurement error and predicted results match well, and the assembly deviation uncertainty of large component is reduced by about 10 per cent compared with the singular value decomposition method.

This paper proposes a method to evaluate and eliminate the influence of random errors of the laser tracker during evaluation process of coordinate translation parameters and assembly deviations. The proposed method would be useful to improve the assembly measurement accuracy through less measurement times.

This paper results from research carried out to survey the various large commercial aerospace engineering component measurement systems. The commercial aircraft manufacturing industry is special due to the size of the components involved. Accuracy constraints remain very close, despite the size, and therefore accurate methods of measurement are necessary to control the quality of the final product. A survey of various current methods of measurement for such components is presented. These methods are based around three main principles: theodolites, photogrammetry, and laser technology. Each method has its own advantages and disadvantages in terms of accuracy, repeatability, range and cost. It is also often necessary to consider what each technique provides in terms of data storage and analysis. Most techniques use computer‐based systems to store results and perform various calculations. These systems also have their own requirements in terms of the environment in which they are used. It is important to consider whether a particular system can be installed in an area suitable to measure the required component, as well as ensuring that the stability requirements are met. In this paper the principles and characteristics of conventional optical tooling, electronic triangulation, electronic trilateration, photogrammetry, laser trackers, and laser scanners are reviewed.

The introduction of automation for the assembly of aircraft wing box structures will require individual components to conform closely to the CAD design specification with regard to shape geometry and dimensional tolerances. Often, due to a variety of previous manufacturing processes, the 3D shape of these large components lose the accuracy of their designed dimensional specifications. Under these circumstances part‐to‐part assembly becomes tedious and it would be impossible to rely on robots to achieve precise assembly in an automated system. For this reason, variations need to be accurately quantified in order to provide a reliable prediction model in aid of any future automated assembly. This paper describes the measurement method used to record the possible variations occurring during the assembly process. The measurements were made using a laser tracker where the results are expected to offer some explanations as to the causes of the variation. The suitability of a laser tracker in a large assembly jig environment is then assessed. This study is based on the work that was carried out at BAE Systems UK, where the Airbus commercial aircraft wings are manufactured.

A report on the vision systems featured at the new TEAM exhibition. The products and applications of three companies are highlighted. Two exhibitors have contrasting approaches to the application of vision: DVT takes the integrated route with “all in” intelligent cameras while Data Translation follows the PC‐based philosophy with separate frame grabbers. The third company discussed is Leica Geosystems and its laser tracker mobile measurement systems used for inspection of large components as well as the control and calibration of robots, machine tools and the like. Leica introduced a new handheld probe for inspecting deep cavities and a new laser radar system that, unlike the tracker, needs no reflectors mounted on the object under inspection.

The purpose of this paper is to present a technique for assessing and comparing the static and dynamic performance of three different models of small six-axis industrial robots using a Renishaw XL80 laser interferometer system, a FARO ION laser tracker and a Renishaw QC20-W telescoping ballbar.

Specific test methods are proposed in this work, and each robot has been measured in a similar area of its working envelope. The laser interferometer measurement instrument is used to assess the static positioning performance along three linear and orthogonal paths. The laser tracker is used to assess the contouring performance at different tool center point (TCP) speeds along a triangular tool path, whereas the telescoping ballbar is used to assess the dynamic positioning performance for circular paths at different TCP speeds and trajectory radii.

It is found that the tested robots behave differently, and that the static accuracy of these non-calibrated robots varies between 0.5 and 2.3 mm. On the other hand, results show that these three robots can provide acceptable corner tracking at low TCP speeds. However, a significant overshoot at the corner is observed at high TCP speed for all the robots tested. It was also found that the smallest increment of Cartesian displacement (Cartesian resolution) that can be taken by the tested robots is approximately 50 μm.

The technique used in this paper allows extremely accurate diagnosis of the robot performance, which makes it possible for the robot user to determine whether the robot is in good or bad condition. It can also help the decision-maker to select the most suitable industrial robot to achieve the desired task with minimum cost and specific application ability.

This paper proposed a new method based on the performance verification approach for solving the robot selection problem for flexible manufacturing systems. Furthermore, despite their importance, bidirectional repeatability and Cartesian resolution are never specified by the manufacturers of industrial robots nor are they described in the ISO 9283:1998 guide, and they are rarely the object of performance assessments. In this work, specific tests are performed to check and quantify the bidirectional repeatability and the Cartesian resolution of each robot.

Optical measurement sensors are increasingly available, often finding application in measurement and inspection of manufactured products. For example, theodolites and laser trackers are already used to calibrate jigs and tooling. Digital photogrammetry is used in dimensional inspection of assemblies such as aircraft wings. Such tasks demand high performance sensors with 2D and 3D capability, large working envelopes, high accuracy, low measurement latency and increased flexibility. The availability of sensors which meet and exceed such criteria is fuelling new possibilities in the manufacturing process itself. Fixed tooling may be eliminated and replaced by flexible fixturing under the control of embedded sensor systems. Sensor technology is reviewed and a novel application presented.

For the measurement of large-scale components in aircraft assembly, the evaluation of coordinate transformation parameters between the coordinate frames of individual measurement systems to the assembly frame is an essential task, which is usually completed by registration of the enhanced reference system (ERS) points. This paper aims to propose an analytical method to evaluate the uncertainties of transformation parameters considering both the measurement error and the deployment error of ERS points.

For each measuring station, the measured coordinates of ERS points are first roughly registered to the assembly coordinate system using the singular value decomposition method. Then, a linear transformation model considering the measurement error and deployment error of ERS points is developed, and the analytical solution of transformation parameters’ uncertainties is derived. Moreover, the covariance matrix of each ERS points in the transformation evaluation is calculated based on a new uncertainty ellipsoid model and variance-covariance propagation law.

For the transformation of both single and multiple measuring stations, the derived uncertainties of transformation parameters by the proposed analytical method are identical to that obtained by the state-of-the-art iterative method, but the solution process is simpler, and the computation expenses are much less.

The proposed uncertainty evaluation method would be useful for in-site measurement and optimization of the configuration of ERS points in the design of fixture and large assembly field. It could also be applied to other registration applications with errors on both sides of registration points.

The purpose of this paper is to propose an on-line iterative compensation method combining with a feed-forward compensation method to enhance the assembly accuracy of a metrology-integrated robot system (MIRS).

By the integration of a six degrees of freedom (6DoF) measurement system (T-Mac), the robot’ movement can be tracked with real-time measurement. With the on-line measured data, the proposed iterative compensation for absolute positioning and the feed-forward compensation for relative linear motion are integrated into the assembly process to improve the assembly accuracy.

It is found that the MIRS exhibits good performance in both accuracy and efficiency with the application of the proposed compensation method. With the proposed assembly process, a component can be automatically aligned to the target in seconds, and the assembly error can be decreased to 0.021 mm for position and 0.008° for orientation on average.

This paper presents a 6DoF MIRS for high-precision assembly. Based on the system, a novel on-line compensation method is proposed to enhance the assembly accuracy. In this paper, the assembly accuracy and the corresponding distance parameter are given by a series of experiments as reference for assembly applications.

In the digital assembly system of large aircraft components (LAC), the docking trajectory of LAC is an important factor affecting the docking accuracy and stability of the LAC. The main content of docking trajectory planning is how to move the LAC from the initial posture and position to the target posture and position (TPP). This paper aims to propose a trajectory planning method of LAC based on measured data.

First, the posture and position error model of the wing is constructed according to the measured data of the measurement points (MPs) and the fork lug joints. Second, the particle swarm optimization algorithm based on the dynamic inertia factor is used to optimize the TPP of the wing. Third, to ensure the efficiency and stability of posture adjustment, the S-shaped curve is used as the motion trajectory of LAC, and the parameters of the trajectory are solved by the generalized multiplier method. Finally, a series of docking experiments are carried out.

During the process of posture adjustment, the motion of the numerical control locator (NCL) is stable, and the interaction force between the NCLs is always within a reasonable range. After the docking, the MPs are all within the tolerance range, and the coaxiality error of the fork lug hole is less than 0.2 mm.

In this paper, the measured data rather than the theoretical design model is used to solve the TPP, which improves the docking accuracy of LAC. Experiment results show that the proposed trajectory method can complete the LAC docking effectively and improve the docking accuracy.