Development of automated assembly systems for large CFRP structures

The Fraunhofer Project Group Joining and Assembly FFM in close cooperation with the Institute of Production Management and Technology (IPMT) develops processes and automated systems for assembly and precision machining of large CFRP structures at the research centre CFK NORD in Stade. Flexible automated assembly systems are nowadays growing in importance in the aircraft manufacturing industry caused by the increase of aircraft production rate, the need to react quickly to design changes and the introduction of light-weight materials such as CFRP (Carbon Fibre Reinforced Plastic) in replacement of heavier metallic materials like aluminium in structures such as fuselage, wings, vertical and horizontal stabiliser, etcetera. Manufactured parts tend to have a unique geometry which leads to a complex assembly. Technologies such as high accuracy positioning systems, non-contact geometry measurement processes and robot offline-programming strategies need to be studied and improved in order to be applied and comply with the specified tolerances in aircraft manufacturing. In this publication fundamental automation solutions will be presented, which were developed for the mounting and processing of CFRP structures using standard industrial robots.