Robotic Spar Assembly Using Metrology-Driven Positioning
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Solution Overview
Problem
Current manual assembly processes for spar assemblies in aircraft are time-consuming, complex, and lack the desired level of quality and consistency, while existing robotic systems face challenges in mobility, flexibility, and accuracy in positioning parts within factory settings.
Innovation Solution
A flexible manufacturing system comprising a mobile tooling system, multiple robotic systems, and a control system that uses metrology data to precisely position components, with a feature locator and robot manager to compute transformations for robotic movement plans, ensuring accurate positioning and assembly within tight tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly processes are used for spar assemblies, then flexibility and adaptability are maintained, but assembly time increases and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robotic system that uses vision guidance and sensor feedback to achieve precise positioning. The robotic system incorporates automated drilling, countersinking, and fastener installation capabilities, eliminating manual labor while maintaining or improving positioning accuracy through electronic control and real-time measurement.
Solution Approach 2:
The system implements feedback mechanisms through sensors and vision systems that continuously monitor component positions and assembly progress. This feedback enables real-time adjustments to robotic movements, ensuring that positioning accuracy is maintained throughout the automated assembly process, thereby resolving the contradiction between automation speed and precision.
2Productivity
If robotic systems are used for assembly operations, then productivity increases, but device complexity and difficulty of operation increase
Solution Approach 1:
The robotic system is designed as a multi-functional platform that can perform various assembly operations including drilling, countersinking, fastener installation, and positioning. By consolidating multiple functions into a single integrated system, the patent reduces the need for multiple separate devices and operators, thereby managing complexity while maintaining high productivity.
Solution Approach 2:
The system incorporates automated programming and self-adjustment capabilities that reduce the need for complex manual configuration. The robotic system can automatically adapt to different assembly tasks through pre-programmed sequences and real-time sensor feedback, simplifying operation despite the underlying system complexity.
3Manufacturing precision
If robotic systems are used for positioning parts, then manufacturing precision improves, but adaptability and ease of operation worsen
Solution Approach 1:
The robotic system employs dynamic positioning and adjustment mechanisms that allow it to adapt to different component configurations and tolerances. The system can modify its positioning strategy in real-time based on sensor feedback and programmed parameters, maintaining high precision while accommodating variations in assembly requirements.
Solution Approach 2:
The system utilizes programmable parameters and adjustable settings that can be modified to suit different assembly tasks. By changing operational parameters such as positioning offsets, tolerance ranges, and movement sequences, the robotic system maintains precision across diverse applications without requiring physical reconfiguration.
Data Source
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AI summary
A method and apparatus for positioning one component relative to another component. First metrology data may be identified for a first component and second metrology data may be identified for a second component. First locations of first features may be identified on the first component using the first metrology data. Second locations of second features on the second component may be identified using the second metrology data. A transformation may be computed based on the first locations identified and the second locations identified for use in modifying a movement plan of a robotic system for positioning the second component relative to the first component.