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Article
Publication date: 7 September 2015

Biao Mei, Weidong Zhu, Huiyue Dong and Yinglin Ke

This paper aims to propose a roadmap to control the robot–subassembly (R–S) coordination errors in movable robotic drilling. Fastener hole drilling for multi-station aircraft…

Abstract

Purpose

This paper aims to propose a roadmap to control the robot–subassembly (R–S) coordination errors in movable robotic drilling. Fastener hole drilling for multi-station aircraft assembly demands a robotic drilling system with expanded working volume and high positioning accuracy. However, coordination errors often exist between the robot and the subassembly to be drilled because of disturbances.

Design/methodology/approach

Mechanical pre-locating and vision-based robot base frame calibration are consecutively implemented to achieve in-process robot relocation after station transfer. Thus, coordination errors induced by robotic platform movements, inconsistent thermal effects, etc. are eliminated. The two-dimensional (2D) vision system is applied to measure the remainder of the R–S coordination errors, which is used to enhance the positioning accuracy of the robot. Accurate estimation of measured positioning errors is of great significance for evaluating the positioning accuracy. For well estimation of the positioning errors with small samples, a bootstrap approach is put forward.

Findings

A roadmap for R–S coordination error control using a 2D vision system, composed of in-process relocation, coordination error measurement and drilled position correction, is developed for the movable robotic drilling.

Practical implications

The proposed roadmap has been integrated into a drilling system for the assembly of flight control surfaces of a transport aircraft in Aviation Industry Corporation of China. The position accuracy of the drilled fastener holes is well ensured.

Originality/value

A complete roadmap for controlling coordination errors and improving positioning accuracy is proposed, which makes the high accuracy and efficiency available in movable robotic drilling for aircraft manufacturing.

Article
Publication date: 8 November 2022

Md. Helal Miah, Jianhua Zhang and Ravinder Tonk

Regarding the assembly of the fuselage panel, this paper aims to illustrate a design of pre-assembly tooling of the fuselage panel for the automatic drilling riveting machine…

Abstract

Purpose

Regarding the assembly of the fuselage panel, this paper aims to illustrate a design of pre-assembly tooling of the fuselage panel for the automatic drilling riveting machine. This new prototype of pre-assembly tooling can be used for different types and sizes of fuselage panels. Also, apply to the automated drilling and riveting machine of the fuselage panels.

Design/methodology/approach

Based on the different structures of the fuselage panel, the position of the preassembly tooling components, location of the clamp and position of the fuselage panel are determined. After that, the overall structure of the preassembly tooling is designed, including the movable frame and the cardboard. The cardboard positioning module and the clamping module formulate a detailed design scheme of preassembly tooling for the fuselage panel. The structure of the pre-assembled tooling is optimized by static analysis. The result of the overall design is optimized by using MATLAB and CATIA-V5 software, and the results meet the condition of the design requirements.

Findings

The traditional assembly process of the fuselage is to install the fuselage panel on the preassembly tooling for positioning the hole and then install it on the automated drilling and riveting tooling for secondary tooling. Secondary tooling can consume assembly errors of the fuselage panel. The new prototype of flexible tooling design for the fuselage panel not only avoids the secondary tooling error of the fuselage panel but also meets the preassembly of different types of fuselage panels.

Research limitations/implications

The further development of the flexible tooling design of the fuselage panel is to reduce the error of sliding tooling due to friction of the sliding components. Because if the assembly cycle is increased, the sliding parts will lose material due to corrosion. As a result, the repeated friction force is the root cause of the positioning error of sliding parts. Therefore, it is necessary to engage less corrosive material. Also, the lubricant may be used to reduce the corrosion in minimizing the positioning error of the sliding tool components. In addition, it is important to calculate the number of assembly cycles for efficient fuselage panel assembly.

Originality/value

According to the structure and assembly process characteristics of the fuselage panel, the fuselage panel preassembly tooling can optimize the assembly process of the fuselage panel and have certain practical application values.

Details

Aircraft Engineering and Aerospace Technology, vol. 95 no. 2
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 22 March 2021

Dongmin Li, Guofang Ma and Jia Li

It is essential to level the drilling platform across which a drilling robot travels in a slant underground coal mine tunnel to ensure smooth operation of the drill rod. However…

Abstract

Purpose

It is essential to level the drilling platform across which a drilling robot travels in a slant underground coal mine tunnel to ensure smooth operation of the drill rod. However, existing leveling methods do not provide dynamic performance under the drilling conditions of the underground coal mine. A four-point dynamic leveling algorithm is presented in this paper based on the platform attitude and support rod displacement (DLAAD). An experimental drilling robot demonstrates its dynamic leveling capability and ability to ensure smooth drill rod operations.

Design/methodology/approach

The attitude coordinate of the drilling robot is established according to its structure. A six-axis combined sensor is adopted to detect the platform attitude, thus revealing the three-axis Euler angles. The support rod displacement values are continuously detected by laser displacement sensors to obtain the displacement increment of each support rod as needed. The drilling robot is leveled according to the current support rod displacement and three-dimensional (3 D) attitude detected by the six-axis combined sensor dynamically.

Findings

Experimental results indicate that the DLAAD algorithm is correct and effectively levels the drilling platform dynamically. It can thus provide essential support in resolving drill rod sticking problems during actual underground coal mine drilling operations.

Practical implications

The DLAAD algorithm supports smooth drill rod operations in underground coal mines, which greatly enhances safety, reduces power consumption, and minimizes cost. The approach proposed here thus represents considerable benefits in terms of coal mine production and shows notable potential for application in similar fields.

Originality/value

The novel DLAAD algorithm and leveling control method are the key contributions of this work, they provide dynamical 3 D leveling and help to resolve drill rod sticking problems.

Details

Assembly Automation, vol. 41 no. 2
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 11 April 2022

Junshan Hu, Xinyue Sun, Wei Tian, Shanyong Xuan, Yang Yan, Wang Changrui and Wenhe Liao

Aerospace assembly demands high drilling position accuracy for fastener holes. Hole position error correction is a key issue to meet the required hole position accuracy. This…

Abstract

Purpose

Aerospace assembly demands high drilling position accuracy for fastener holes. Hole position error correction is a key issue to meet the required hole position accuracy. This paper aims to propose a combined hole position error correction method to achieve high positioning accuracy.

Design/methodology/approach

The bilinear interpolation surface function based on the shape of the aerospace structure is capable of dealing with position error of non-gravity deformation. A gravity deformation model is developed based on mechanics theory to efficiently correct deformation error caused by gravity. Moreover, three solution strategies of the average, least-squares and genetic optimization algorithms are used to solve the coefficients in the gravity deformation model to further improve position accuracy and efficiency.

Findings

Experimental validation shows that the combined position error correction method proposed in this paper significantly reduces the position errors of fastener holes from 1.106 to 0.123 mm. The total position error is reduced by 43.49% compared with the traditional mechanics theory method.

Research limitations/implications

The position error correlation method could reach an accuracy of millimeter or submillimeter scale, which may not satisfy higher precision.

Practical implications

The proposed position error correction method has been integrated into the automatic drilling machine to ensure the drilling position accuracy.

Social implications

The proposed position error method could promote the wide application of automatic drilling and riveting machining system in aerospace industry.

Originality/value

A combined position error correction method and the complete roadmap for error compensation are proposed. The position accuracy of fastener holes is reduced stably below 0.2 mm, which can fulfill the requirements of aero-structural assembly.

Article
Publication date: 26 October 2018

Biao Mei, Weidong Zhu and Yinglin Ke

Aircraft assembly demands high position accuracy of drilled fastener holes. Automated drilling is a key technology to fulfill the requirement. The purpose of the paper is to…

288

Abstract

Purpose

Aircraft assembly demands high position accuracy of drilled fastener holes. Automated drilling is a key technology to fulfill the requirement. The purpose of the paper is to conduct positioning variation analysis and control for an automated drilling to achieve a high positioning accuracy.

Design/methodology/approach

The nominal and varied connective models of automated drilling are constructed for positioning variation analysis regarding automated drilling. The principle of a strategy for reducing positioning variation in drilling, which shortens the positioning variation chain with the aid of an industrial camera-based vision system, is explored. Moreover, other strategies for positioning variation control are developed based on mathematical analysis to further reduce the position errors of the drilled fastener holes.

Findings

The propagation and accumulation of an automated drilling system’s positioning variation are explored. The principle of reducing positioning variation in an automated drilling using a monocular vision system is discussed from the view of variation chain.

Practical implications

The strategies for reducing positioning variation, rooted in the constructed positioning variation models, have been applied to a machine-tool based automated drilling system. The system is developed for a wing assembly of an aircraft in the Aviation Industry Corporation of China.

Originality/value

Propagation, accumulation and control of positioning variation in an automated drilling are comprehensively explored. Based on this, the positioning accuracy in an automated drilling is controlled below 0.13 mm, which can meet the requirement for the assembly of the aircraft.

Article
Publication date: 4 April 2016

Mohammad Ali Dehghani and Mohammad Bagher Menhaj

The purpose of this paper is achieving a leader–follower formation of unmanned aerial vehicles which is a cooperative scenario inspired by formation flying of living organisms…

Abstract

Purpose

The purpose of this paper is achieving a leader–follower formation of unmanned aerial vehicles which is a cooperative scenario inspired by formation flying of living organisms such as geese. Designing a control strategy based on only vision measurement (without radio communication) and keeping connectivity in vision are important challenges in the formation flying problem which is the base of formation flying in living organisms.

Design/methodology/approach

To achieve the mentioned purposes, a feedback linearization technique is used. Moreover, a Takagi-Sugeno-based supervisory control strategy for visibility maintenance combined with an acceleration estimator to compensate the leader maneuvers is proposed.

Findings

The authors conclude that by using practical seeker sensors, all the mentioned objectives (under the proposed strategy) can be satisfied.

Originality/value

Keeping formation and visibility maintenance in the presence of the leader maneuver are the main contributions of the paper.

Details

Assembly Automation, vol. 36 no. 2
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 1 June 2005

Brian Rooks

To review presentations on assembly and joining given at a seminar, “The changing face of robotics: inside and outside the factory”, organised by the UK Institution of Electrical…

1525

Abstract

Purpose

To review presentations on assembly and joining given at a seminar, “The changing face of robotics: inside and outside the factory”, organised by the UK Institution of Electrical Engineers.

Design/methodology/approach

Details are given of three presentations. The first is by Dr Phil Webb of the University of Nottingham, who described a project to develop a flexible robotic cell capable of riveting and assembling aero‐structure components, in which a new method of “simulation‐based control” evolved. In the second, Pearl Agjakwa of Nottingham University and Craig Johnson of Rolls Royce talked about shape metal deposition, a process by which layers of weld are deposited by robot to form complex aerospace components with minimal tooling and short lead times. The final presentation was by Dr Wolfgang Kölbl of Meta Vision Systems on laser vision robot guidance. Applications in automotive and a new cross vision sensor were described, the latter being applicable to hole location such as for drilling and riveting.

Findings

Robotics inside the factory is extending into new areas of assembly and fastening and is now finding applications in the aerospace industry and not just in automotive.

Originality/value

Provides a review of some new assembly‐related process developments in robotics.

Details

Assembly Automation, vol. 25 no. 2
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 1 October 2005

P. Webb, S. Eastwood, N. Jayaweera and Y. Chen

Describes the application of standard industrial robots to the assembly and riveting of aerostructure sub‐assemblies.

1767

Abstract

Purpose

Describes the application of standard industrial robots to the assembly and riveting of aerostructure sub‐assemblies.

Design/methodology/approach

Describes the design and operation of special purpose end‐effectors for assembly and solid riveting and their integration in an aerostructure sub‐assembly fabrication cell. The robots are controlled by a novel control system which allows the cell to compensate for distortion and misalignment of the components.

Findings

Demonstrates that with advanced control standard industrial robots can be used to assemble aerostructure sub‐assemblies.

Originality/value

Introduces techniques for compensating for the inherent distortion that occurs in airframe components during manufacture. This is an enabling technology that will significantly increase the number of possible applications for robots in the assembly of aerostructures.

Details

Industrial Robot: An International Journal, vol. 32 no. 5
Type: Research Article
ISSN: 0143-991X

Keywords

Abstract

Details

Process Automation Strategy in Services, Manufacturing and Construction
Type: Book
ISBN: 978-1-80455-144-8

Article
Publication date: 1 January 1987

A.C. Traub and J. Evans

Infra‐red thermal monitoring of drill bit temperatures is just coming into use for laminate drilling. Although not yet in production use, the method has been evaluated, with…

Abstract

Infra‐red thermal monitoring of drill bit temperatures is just coming into use for laminate drilling. Although not yet in production use, the method has been evaluated, with promising results, in the engineering laboratories of four major manufacturers. In addition, it has been used with excellent results as a research tool during studies of interactions between drill wear, drill temperature, compositions of entry and backup materials, hole quality, and other parameters of the drilling process. This paper will outline the principles of infra‐red thermometry and will then discuss the present and the anticipated applications to laminate drilling.

Details

Circuit World, vol. 13 no. 2
Type: Research Article
ISSN: 0305-6120

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