Robotic Tool Module Self-Alignment for Aircraft Wing Assembly
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Solution Overview
Problem
Existing automated assembly systems for aircraft wing boxes face challenges in accurately aligning tool modules without manual intervention, particularly when the tool module is misaligned with the aperture, leading to restricted movement and inefficiencies in drilling and fastening operations.
Innovation Solution
An automated self-aligning system comprising a first robot arm with a clamping end effector and a second robot arm with a tooling end effector, equipped with a load sensor and a control system that cycles the tool module through multiple degrees of freedom in a predetermined sequence to align it with the aperture, ensuring proper insertion and operation without excessive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool module is manually aligned with the aperture, then alignment accuracy is improved, but automation level deteriorates
Solution Approach 1:
The system enables the tool module to automatically align itself with the aperture through feedback from the load sensor and cyclic movement in multiple degrees of freedom, eliminating the need for manual alignment intervention while maintaining high alignment accuracy
Solution Approach 2:
The load sensor provides real-time feedback on the insertion load, which the control system uses to detect misalignment conditions and trigger cyclic movement of the tool module until proper alignment is achieved, thereby maintaining automation while ensuring precision
2Speed
If the second robot arm moves the tool module directly into the aperture without alignment adjustment, then operation speed is improved, but alignment accuracy deteriorates
Solution Approach 1:
The system performs preliminary alignment checks by monitoring insertion load before final insertion, and executes cyclic alignment adjustments only when misalignment is detected, allowing most operations to proceed at high speed while ensuring accuracy when needed
Solution Approach 2:
The system dynamically adjusts the insertion process by transitioning from direct high-speed insertion to cyclic multi-degree-of-freedom movement when misalignment is detected, and returns to high-speed insertion once alignment is achieved, optimizing both speed and accuracy
3Productivity
If excessive force is applied to insert the misaligned tool module, then insertion is achieved, but damage or deformation occurs
Solution Approach 1:
The load sensor continuously monitors the insertion load and provides feedback to the control system, which prevents excessive force application by detecting misalignment conditions and triggering cyclic alignment movements before final insertion, thereby avoiding damage while ensuring successful insertion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates fully automated assembly by automatically adjusting the orientation and position of the tool module to align with the aperture, enhancing the accuracy and efficiency of drilling and fastening operations in aircraft wing assembly, reducing manual intervention and assembly time.
Implementation Method 1
a load sensor coupled to the tooling end effector; wherein the load sensor is arranged to determine a load in the direction of insertion of the tool module
Data Source
AI summary
An automated self-aligning system is disclosed including a first robot arm attached to a clamping end effector including clamp jaws for clamping either side of a workpiece and with an aperture in one of the clamp jaws. A second robot arm is attached to a tooling end effector including a tool module carrying a tool. The tool module is insertable into the aperture and the tool is adapted to perform an operation on the workpiece. The second robot arm is arranged to move the tool module so as to move the tool module in a direction of insertion so as to insert the tool module into the aperture. A load sensor coupled to the tooling end effector and is arranged to determine a load in the direction of insertion of the tool module. The tooling end effector is further arranged to move the tool module with respect to the second robot arm in a plurality of degrees of freedom different than the insertion direction.