Robots boost assembly operations

Automation specialist Kuka has devised a flexible robotic solution for performing a variety of drilling and fastening tasks on the upper and lower wing covers of a lateral wing box demonstration unit being built at the Airbus facility in Filton.

The wing box is due to be delivered to Toulouse this summer where it will undergo a series of rigorous structural tests. The results will then be evaluated by Airbus to see if the new robotic technology is suitable for use in current as well as future aircraft programmes.

Kuka's collaboration with Airbus is part of the Advanced Low Cost Aircraft Structures (ALCAS) project, a €100 million European Commission-backed research scheme that aims to identify new composite manufacturing and assembly strategies.

The overall objective of the ALCAS project is to maintain and enhance the competitive position of the European aerospace industry in the face of significant challenges from strong global competition. Helping to make a contribution to the reduction of the operating costs of relevant European aerospace products by 15% through the cost-effective full application of carbon fibre composites to aircraft primary structures, ALCAS targets both business jets and large civil airliners.

“Airbus wanted to explore the development of a flexible, re-configurable solution that could undertake a number of tasks on a single system and offer a modular design so that other processes could be added in the future,” explains Kuka's UK aerospace manager, Gary Taylor.

One of the project's main objectives was to improve efficiency by using a horizontal wing build philosophy instead of the conventional vertical manual method, a time-consuming and labour-intensive process.

Due largely to Kuka's expertise, an effective assembly system has been devised that incorporates a number of innovative new technologies such as Kuka's 18 tonne payload OmniMove, a mobile positioning device that provides an alternative to using a crane for manoeuvring the carbon fibre wing covers into the jig.

The OmniMove is also used to position a pair of platform-mounted Kuka robots for drilling holes in the lower wing cover. The assembly system includes an identical pair of robots installed on a high level gantry for the upper wing cover operation.

Two of the robots are equipped with an adaptive guidance device for monitoring the accuracy of the drill head position while the others feature a multi-function end effector specially designed to drill holes ranging in diameter from 6-22mm and a material thickness of up to 110mm.

The design of the robot end effector is another example of new technology specifically developed for the project by Kuka. It not only offers a choice of spindle systems for axial and orbital drilling capabilities, but also other integrated features such as a fastener insertion facility and a non-contact optical measurement probe.

“It has proved to be a good collaboration with Airbus,” concludes Taylor. “This system successfully demonstrates how the latest automation technology can validate the capability for future aircraft manufacturing concepts and help transform time-consuming manual processes into efficient, high performance operations.”

Work undertaken for the ALCAS project will also play a role in the development of new technologies under the Next Generation Composite Wing (NGCW) programme, a multi-million pound research project headed by Airbus and involving 16 other companies including Kuka.

Kuka will also be demonstrating its latest solutions on stand B10, hall 4, at the Farnborough International Airshow.

www.kuka.co.uk