Auto-normalization algorithm for robotic precision drilling system in aircraft component assembly

Tian, Wei; Weixue, Zhou; Zhou, Wei; Liao, Wenhe; Zeng, Yuanfan

doi:10.1016/j.cja.2013.02.029

Cited by 46 publications

(24 citation statements)

References 7 publications

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“…Figure 4 shows a heat map of the robot vibrations experienced within the drilling workspace. The lowest vibration experienced (0.00097 mm) is highlighted by the light blue block in (4, 2), the area of highest vibration (0.00921 mm) is shown by the black block (12,6). The all white blocks are the locations within the workspace that the robot could not reach due to the pose limitations.…”

Section: Vibration Results With the Spindle Offmentioning

confidence: 99%

Optimization of an Autonomous robotic drilling system for the Machining of Aluminum Aerospace Alloys

Pereira¹,

Griffiths²,

Birch³

et al. 2021

Preprint

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This paper aims to identify the capability of a highly flexible industrial robot modified with a high-speed machine spindle for drilling of Aluminum 6061-T6. With a focus on drilling feedrate, spindle speed and pecking cycle, the hole surface roughness and exit burr heights were investigated using the Taguchi design methodology. A state of the art condition monitoring system was used to identify the vibrations experienced during drilling operation and to establish which robot pose had increased stiffness, and thus the optimum workspace for drilling. When benchmarked against a CNC machine the results show that the CNC was capable of producing the best surface finish and the lowest burr heights. However, the robot system matched and outperformed the CNC in several experiments and there is much scope for further optimization of the process. Overall the proposed drilling system is far more flexible than a CNC milling machine and when considering the optimized drilling of aerospace aluminum this robotic solution has the potential to drastically improve productivity.

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Section: Vibration Results With the Spindle Offmentioning

confidence: 99%

Optimization of an Autonomous robotic drilling system for the Machining of Aluminum Aerospace Alloys

Pereira¹,

Griffiths²,

Birch³

et al. 2021

Preprint

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show abstract

“…In DrillTCPActual T HoleFrameActual ͑II͒ , the rotational part RotErr ͑⌸͒ causes the perpendicularity error of the drill axis relative to the subassembly surface, which can be measured and compensated for by using the method in Zhu et al (2014), Tian et al (2013): Figure 5 Roadmap for R-S coordination error control in robotic drilling for multi-station assembly …”

Section: ͑I͒mentioning

confidence: 99%

Coordination error control for accurate positioning in movable robotic drilling

Mei

Zhu

Dong

et al. 2015

Assembly Automation

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2015),"An adaptive BPSO algorithm for multi-skilled workers assignment problem in aircraft assembly lines", Assembly Automation, Vol. 35 Iss 4 pp. 317-328 http://dx. (2015),"Auto-body assembly process fault diagnosis based on a dynamic variation modeling approach", Assembly Automation, Vol. 35 Iss 4 pp. 302-308 http://dx.If you would like to write for this, or any other Emerald publication, then please use our Emerald for Authors service information about how to choose which publication to write for and submission guidelines are available for all. Please visit www.emeraldinsight.com/authors for more information. About Emerald www.emeraldinsight.comEmerald is a global publisher linking research and practice to the benefit of society. The company manages a portfolio of more than 290 journals and over 2,350 books and book series volumes, as well as providing an extensive range of online products and additional customer resources and services.Emerald is both COUNTER 4 and TRANSFER compliant. The organization is a partner of the Committee on Publication Ethics (COPE) and also works with Portico and the LOCKSS initiative for digital archive preservation. AbstractPurpose -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.

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“…In aircraft assembly, the connection quality of lightweight stacked structures directly affects the fatigue performance and service life of the aircraft. To improve the drilling and connection quality of aircraft components, many automatic drilling and riveting systems are introduced into aircraft manufacturing industries [4][5][6]. During the automatic drilling process of stacked metal plates, one of the most outstanding issues is the formation of interlayer burr [7,8].…”

Section: Introductionmentioning

confidence: 99%

Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

et al. 2020

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Interlayer burrs formation during drilling of stacked plates is a common problem in the field of aircraft assembly. Burrs elimination requires extra deburring operations which is time-consuming and costly. An effective way to inhibit interlayer burrs is to reduce the interlayer gap by preloading clamping force. In this paper, based on the theory of plates and shells, a mathematical model of interlayer gap with bidirectional clamping forces was established. The relationship between the upper and lower clamping forces was investigated when the interlayer gap reaches zero. The optimization of the bidirectional clamping forces was performed to reduce the degree and non-uniformity of the deflections of the stacked plates. Then, the finite element simulation was conducted to verify the mathematical model. Finally, drilling experiments were carried out on 2024-T3 aluminum alloy stacked plates based on the dual-machine-based automatic drilling and riveting system. The experimental results show that the optimized bidirectional clamping forces can significantly reduce the burr heights. The work in this paper enables us to understand the effect of bidirectional clamping forces on the interlayer gap and paves the way for the practical application.

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Auto-normalization algorithm for robotic precision drilling system in aircraft component assembly

Cited by 46 publications

References 7 publications

Optimization of an Autonomous robotic drilling system for the Machining of Aluminum Aerospace Alloys

Optimization of an Autonomous robotic drilling system for the Machining of Aluminum Aerospace Alloys

Coordination error control for accurate positioning in movable robotic drilling

Modeling and Optimization of Bidirectional Clamping Forces in Drilling of Stacked Aluminum Alloy Plates

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