An Integrated Architecture for Robotic Assembly and Inspection of a Composite Fuselage Panel with an Industry 5.0 Perspective

Author:

Lettera Gaetano1ORCID,Natale Ciro1ORCID

Affiliation:

1. Dipartimento di Ingegneria, Università degli Studi della Campania Luigi Vanvitelli, 81031 Aversa, Italy

Abstract

Aeronautical robotic applications use quite large, heavy robots with huge end effectors that are frequently multifunctional. An assembly jig to hold a fuselage panel and two medium-sized six-axis robots fixed on linear axes, referred to as the internal and the external robot with respect to the curvature of the panel, make up the Lean robotized AssemBly and cOntrol of composite aeRostructures (LABOR) work cell. A distributed software architecture is proposed in which individual modules are developed to execute specific subprocesses, each implementing innovative algorithms that solve the main drawbacks of state-of-the-art solutions. Real-time referencing adopts a point-cloud-based strategy to reconstruct and process the part before drilling, avoiding hole positioning errors. Accurate concentric countersink diameters are made possible through the automatic adjustment of the drilling tool with respect to the skin panel, which guarantees its orthogonality, as well as the implementation of process parameter optimization algorithms based on historical results that compensate for the wear of the drilling bits. Automatic sealing and fastening strategies that involve the measurement of the main fastener quality parameters allow for the complete verification of the entire assembly process of each part. Additionally, an advanced multimodal perception system continuously monitors the collaborative workspace to ensure safe human–robot collaboration (HRC) tasks. Through this integrated architecture, LABOR substantially reduces expenses and facilitates maintenance and programming.

Funder

European Commission

Publisher

MDPI AG

Subject

Electrical and Electronic Engineering,Industrial and Manufacturing Engineering,Control and Optimization,Mechanical Engineering,Computer Science (miscellaneous),Control and Systems Engineering

Reference37 articles.

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3. (2023, November 19). Global Market Forecast 2019–2038. Available online: https://www.airbus.com/aircraft/market/global-market-forecast.html.

4. (2023, November 19). Airbus Inaugurates New A320 Structure Assembly Line in Hamburg. Available online: https://www.airbus.com/en/newsroom/press-releases/2019-10-airbus-inaugurates-new-a320-structure-assembly-line-in-hamburg.

5. (2023, November 19). Bombardier to Combine Efficiency and Quality in Manufacturing of CSeries Aircraft. Available online: https://bombardier.com/en/media/news/bombardier-combine-efficiency-and-quality-manufacturing-cseries-aircraft.

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