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Accuracy examination of an adaptive robot joining process for the automated assembly of large CFRP structures

: Schmick, Fabian; Borrmann, Christof; Wollnack, Jörg

Estorff, O. von:
5th International Workshop on Aircraft System Technologies 2015. Proceedings : February 24 - 25, 2015, Hamburg, Germany
Aachen: Shaker, 2015 (Berichte aus der Luft- und Raumfahrttechnik)
ISBN: 978-3-8440-3319-9
International Workshop on Aircraft System Technologies (AST) <5, 2015, Hamburg>
Fraunhofer IFAM ()

The present paper examined an automated joining process for large CFRP aircraft parts. This was demonstrated for the process of mounting an integral frame into a large CFRP shell. To join the frame into the shell a standard industrial robot was used together with 3D measurement devices. This combination allowed the adaptive calculation of a varying position and orientation (pose) of the frame due to the unique geometrical properties of the CFRP components. The final frame pose was thereby independent of an accurate cell layout because of automated measuring routines regarding all relevant components involved in the joining process. In order to guarantee a high accuracy of the final mounting pose the joining process was based on an adaptive gap analysis. The virtual calculation of the resulting gap between frame and shell was used to determine the final frame pose, but also provided the data for the automated application of adhesive on the frame. In this paper the joining process was investigated in terms of repeatability and absolute accuracy of the final pose regarding the frame in the shell. The results showed a high dependency of the resulting pose and the gripper that was used to mount the frame. It was shown that the used process was feasible of mounting large frames into CFRP shell components based on a virtual gap analysis. All measurements to determine the pose of the cell components were done with a laser tracker.