Automated Assembly of Aircraft Structures -...

Automated Assemblyof Aircraft StructuresTRAINING MODULES

for Young Researchers, Master

and Doctoral Students

2013

National Aerospace University

“KhAI”

Automated Assemblyof Aircraft Structures

TRAINING MODULEfor Young Researchers, Master and Doctoral Students

Prepared in the frame of the FP7 KhAI-ERA project activities

2013

National Aerospace University “KhAI”

Published by the National Aerospace University “KhAI” in 2013

Advanced Assembly Processes in Aircraft Manufacturing

This training modules collection was jointly prepared by the National Aerospace University “KhAI” andFraunhofer IFF in the frame of FP7 KhAI-ERA project training development activities. It is intended forYoung Scientists, Master and Doctoral Students.

Included to this issue training modules: The training module states the directions and trends ofdevelopment of modern technologies of aircraft structures assembly; introduces the concept of anautomated assembly-line production of aviation enterprise, implemented with the help of special flexibleCNC fixtures and robotic systems on the basis of assembly method using virtual bases for the conditions offrequent change of aircraft production objects; new methods and tools, algorithms and software, thatimplement the support of technically grounded decision-making by technologist during the development oftechnological processes of aircraft assembly production using automated assembly lines.

Reproduction is authorised provided the source is acknowledged. No use of this publication may be madefor resale or for any other commercial purpose.

Available on-line at http://khai-era.khai.edu/en/site/training-modules.html

For enquiries, inputs and feedback on the use of this document please contact:

International S&T Projects Office

National Aerospace University “KhAI”

17Chkalova str., Kharkov, 61070, Ukraine

Phone: +38 (057) 788 40 60

Fax: +38 (057) 719 04 73

e-mail: [email protected]

LEGAL NOTICE

Neither the European Commission nor any person acting on behalf of the Commission is responsible for theuse, which might be made, of the following information.

The views expressed in this report are those of the authors and do not necessarily reflect those of theEuropean Commission.

© KhAI-ERA Consortium, 2013

Foreword

The rapid progress of aviation science and technology in the last forty years haveallowed to create aircrafts capable to fly at hypersonic speeds, to carry up to 525passengers at the same time on intercontinental routes (the base case A380), to liftup to 250 tons of cargo (AN-225), to carry out a flight in all weather conditions andto route by commands of on-board computer. However, the most common typeof the aircraft in the world is a lightweight aircraft. Along with other general aviationaircrafts, lightweight aircrafts now constitute up to 97% of the global civilaviation fleet.In spite of the high necessity of Civil Aviation, orders for these planes remainunfulfilled. Domestic manufacturer cannot provide a production program with highquality and in the shortest possible time due to the low level of productionpreparation.Passenger and transport aircrafts have a short series of production, but have a largerange of assembly units (flat units, panels), and light aircrafts of general aviationhave no a large range of assembly units, but have a large series of production andmany modifications.Frequent changes of production objects or significant design modifications duringthe serial production lead to significant changes in all technological processes thatparticularly affects the assembly and installation works, assembly methods, linkingdiagrams of the technological equipment and the process of change or reworking ofcomplex, labor intensive and metal intensive jigs. Assembly and installation workconstitute together with the testing and controls processes up to 60% of the totalcomplexity of aircraft manufacturing and more than 65% of the total primaryproduction cycle.

Yu.A. VorobyovNational Aerospace University «Kharkiv Aviation Institute»

V.V. VoronkoNational Aerospace University «Kharkiv Aviation Institute»

I.A. VoronkoNational Aerospace University «Kharkiv Aviation Institute»

Authors

Yu.A. VorobyovNational aerospace university «Kharkiv aviation institute»

Professor, PhD

Author of more than 140 scientific papers in the field oftechnology of assembly and installation works in aircraft industry,has worked with Boeing Company, Joint Stock Company «UnitedAircraft Corporation» (UAC), Ukrainian Research Institute ofAviation Technology and others

V.V. VoronkoNational aerospace university «Kharkiv aviation institute»

Ass. Professor, PhD

Deals with automated assembly lines in conditions of computer-integrated technologies of robotic systems for single and serialaircraft production

I.A. VoronkoNational aerospace university «Kharkiv aviation institute»

PhD student

Deals with the increase of aircraft structures lifetime

Content

Module 1 Automated assembly of aircraft structures 9

Yu.A. Vorobyov, V.V. Voronko, I.A. Voronko, National aerospace university«Kharkiv aviation institute»

1. The main directions and tendencies of developing the technologies ofaircraft structures assembly 12

2. The concept of automated line assembly of aircraft structures 17

3. Formalization and algorithmization of assembly processes in aircraftmanufacturing 22

Module 1 – Automated assembly of aircraft structures

Prepared in the frame of the FP7 KhAI-ERA project 9

Training Module

Automated assembly of aircraft structures

Yu.A. Vorobyov, V.V. Voronko, I.A. Voronko

National Aerospace University «Kharkiv Aviation Institute»

2013



Introduction

Significant specific weight during the implementation of assembly and installation works have thecosts for the operations of mutual coordination of parts and sub-assemblies during theirinstallation, fixation in assembly position, the cost for joining of structure elements, manufacturingof jigs templates. These costs are largely determined by a significant amount of manual works, anddepend on the division scheme, assembly diagram, accepted assembly methods, the level ofinterchangeability and structure workability. The growth of production volume in the assemblyproduction is achieved mainly by expanding the front of work and increase of workers number.

Cause of high labor intensity and the prime cost of assembly and installation works in the aviationindustry, as well as a considerable duration of the production cycle is the low level ofmechanization and automation of assembly operations, and the use of outdated methods ofassembly and linking.

Training Objectives

The objective of the project is to increase the efficiency and reduce the time of preparingand manufacturing aircraft structures by means of automated line assembly and roboticsystems for frequent replacement of aircraft objects with a lot of details in single, small-batch and mass production.

Module components

The main directions and tendencies of developing the technologies of aircraft structuresassembling

The concept of automated line assembly of aircraft structures

Formalization and algorithmization of assembly processes in aircraft manufacturing

Target audience

Training Module is intended for Young Scientists, Master and Doctoral Students.

Automated Assembly of Aircraft Structures

12 Prepared in the frame of the FP7 KhAI-ERA project

National aerospace university “Kharkiv Aviation Institute”Aircraft Manufacturing Processes Department

THE MAIN DIRECTIONS AND

TENDENCIES OF DEVELOPING THE

TECHNOLOGIES OF AIRCRAFT

STRUCTURES ASSEMBLING


Structure of the airplane An-140




The classification of the light aircraft of general use


PRINCIPAL DIRECTIONS AND TENDENCIES OF

DEVELOPMENT

OF FOREIGN TECHNOLOGIES AIRCRAFT ASSEMBLY

STRUCTURES

1. The usage of flexible portable system of positioning the members

of the technological systems.

2. The usage of realigned assembly tooling instead of special.

3. The application of flexible hybrid robots.

4. The usage of electrical executive members of the system of

mounting fastening elements.




The usage of flexible portable system of positioning the members of thetechnological systems

Package of Flex Mini Track system Flexible track (on the left) andFlex Mini Track prototype (on the

right)

General view of multi-purpose butt machineGeneral view of portable

tool for cutting off the stock


The flexible (realigned) assembly tooling

General view of three-point PCM T9000

Drilling and chamfering of airplane’sA340 elevator

Sandwich-panels processing

Diagram of comparing flexible and specialassembly fixtures




Flexible hybrid robots

Performing operations in the wing box

General view of the Snake-Arm robot Principle of control with thehelp of rods


The use of fully electricsystems of performing junctions

In contrast to hydraulic systems these systems have the following advantages:

no leakage of power fluid;

smaller overall dimensions;

the possibility of drilling multi-layer packets (PCM/Ti/Al);

flexible modular extensible design;

improved repairability;

high speed of mounting the fastener (up to 17 assembly elements per

minute);

a lower cost.




Load-carrying conveyorOverhead conveyor

In automobile manufacturing the following methods of

assembly are used:

- method of full and partial changeability;

- method of group changeability;

- method of assembly with fitting the details as applicable;

- method of assembly with adjusting.

Line assembly in automobile manufacturing


The use of line assembly in aircraft manufacturing




The concept of automated lineassembly of aircraft structures


Device for attachment theparts of the tail section

on the conveyor machine

The conveyor line of the wing assembly in the Stalin plant (1945)

Device for attachment the parts ofa new section on the conveyor machine

Conveyor line of general wing assembly in building ways




Structural and technological breakdown of the airframe


Classification of units and panels of aircraft structures




Automated line assembly of the unit consists of the following basic operations:

1) capture the robot takes the details and determines them in space (scanning

and other methods of determining the size of the details), if needed the robot

returns details to modify them;

2) the components are installed in required position relative to each other;

3) the details are fixed in assembled position (belts, walls);

4) the details are held in assembled position(supports, brackets, fittings, etc.);

5) the details are connected in different ways: by rivets, bolts, welding, soldering,

gluing.

In general, a typical procedure of total technological process of automated lineassembly can be represented by the equation:

К,У,В,C),a(УФ),a(УФ,,C),a(УФ),a(УФP

ni1nini1ni2i1i1i1i


Methods of assembling the aircraft structures




Procedure of forming the methods of couplingaircraft structures


A special-purpose realigned device with CNC for flat nodes

Longeron assembly

Frame assembly




Element of special-purpose realigned device with CNC for units assembly

Element of special-purposerealigned device with CNC

for panels assembly


Classification of errors affecting the accuracy of the assembly according to virtualdatabase

Errors of specialized realigned device with CNCduring the formation of the theoretical contour

Errors of mutual linking of contours of the basic detail and the installed components(consist of the sum of robot’s errors and errors of determination the details in space

with the help of scanners, capacity factor and other methods)

space.det.rob.link.mut

чпу_с_спп_ТК

Errors depending on the method of assembly according to virtual databases




Errors of manufacturing SRD CNC_with_SRD.manuf

Errors of manufacturing the basic detail and theassembly element (of the installed details) .bas

Errors not depending on the method of assembly according to virtual databases

Errors arising as a result of deforming thedetails and the assembly element afterconnection

.con

Errors caused by applying forces to theconstruction with the tool (of the equipment)in the process of assembling

.fix

Errors arising as a result ofdeforming the details and the assembly elementunder the influence oftheir own weight

.deflec

Total error influenced the assembly accuracy according to virtual databases is equal:

.deflec.fix.con

.basSRD.prodspace.det.robcnc_with_srd_TCCNC_with_SRD


FORMALIZATION AND ALGORITHMIZATIONOF ASSEMBLY PROCESSES

IN AIRCRAFT MANUFACTURING




STRUCTURAL DECOMPOSITION OF THE AIRFRAME

:

1 1 1 1 1 1 1 1i i i i i i i ij k l m r s v qPlS AS OS SS PS US DS P K

, 1..ij ASAS j n

, 1..ik OSOS k n

, 1..il SSSS l n

, 1..im PSPS m n

, 1..ir USUS r n

, 1..is DSDS s n

1ivP

units

bays

sectionspanels

nodesdetails

purchased products

fastener 1iqK

Types of

assembly (nodes,

panels)

Basic detail Wireframe elements Details for transferring centred

forces

Fastening elements Presence of

compensators

Rib Wall Belts, supports, brackets Carriers, fittings Rivets, bolts +

Frame Wall Belts, supports Carriers, fittings Rivets +

Longeron Wall Belts, supports Carriers, fittings Rivets, bolts +

Panel Boarding Belts, stringers Carriers, fittings Bolts, anchor mount

attachment

+

Partitions Wall Belts, angles, forge No (dispersed force from pressure) Rivets

Walls Wall Belts, supports, brackets Carriers Rivets, bolts +

Classification of the details included in various kinds of assemblies


MODEL OF ASSEMBLY PROCESSES IN THE AIRCRAFT PLANT

FPA FA SUA Assembling aircraft production

compartment of finalassembling

compartment ofaggregate assembling

SUA LCA ASP IDC ASB

Sections of: component assembly, assembly of panels, units and baysBinary relation between airframeelements and workplaces of assembly

,RM

RMk z

l

D

m

r

OS

SSS

PS

US

1 1

,

RM

RMz j

j

RM T

nrm n n

T

ST

Determining the specialization ofassembly workplace

Workplace of the assembly

Teh O Per zI RM

Formalization of route technological processes

;21 inY YYYYR

Technological process of series assembly based on basic technological operations

Technological process based on technological equipment

inZ ZZZZR 21

),,,,0,1,,,,(

yyyyexyfR ki

where yi – basic operators, describing the actions according to algorithms; хk –describe the conditions of jumps according to algorithms; е – describes jump accordingto algorithm without performance of basic operators; – empty operator, which canplay the role of indicator of algorithm stop; 1,0 – identically true, identically falseconditions; – signature of basic operations of RSA, describing the rules ofjumping according to algorithm (multiplication is a consistent performing of TM,conjunction is a parallel performing of TM, disjunction is performing of TM after controloperations, iteration is a periodic performing of TM).

yyyy ;;;




MODEL OF TECHNOLOGICAL PROCESS OF ASSEMBLING PRODUCTION OF NODES

1 2 3 4

1 2 3 4 5 6 7 8 91 2 3 4R Y Y Y Y Y Y Y Y Y


STRUCTURE OF FLEXIBLE PRODUCTION MODULE OF ASSEMBLING FLATNODES

• specialized realigneddevices with computer

numerical control( SRDwith CNC),

•Multi-purposemanipulation robot (MMR),

•Tooling system ofcoordinate metrology

(SCM)

•automated store(AS),•

•Robotized deviceproviding connection withtool and equipment store

(RDC),

•Automated workplace(AW).

SCM

SCM

AW

SRD with CNCMMR

AW




Portal SCM Bridge SCM Coordinate measuring arm

Rack-mount SCM Console SCM Laser tracker

Tooling system of coordinate metrology


THE STRUCTURE OF SOFTWARE OF FLEXIBLE PRODUCTION MODULE OFASSEMBLING THE FLAT KNOTS

CPTP– central program of technological processPTTE – program of transferring the technological equipmentSSCM– software of system of coordinate metrology




The structure of the software


The example of the software work

Assembled nodeSupport setting

Main program window Transporting the holders into working position



References

1. Reid Eric. Development of Portable and Flexible Track Positioning System for AircraftManufacturing Processes / Eric Reid // Automated Fastening / Assembly & Tooling inAerospace. – SAE International, 2007. – P. 11-16.

2. Heithus Jorg. Universal Splice Machine / Jorg Heithus and Patrick Wishall // AutomatedFastening / Assembly & Tooling in Aerospace. – SAE International, 2007. – P. 17-20.

3. Richards Barry. Lug Cutting and Trimming of the Carbon Fibre Wing Panels of the AirbusA400 m with Portable Hand Positioned Tools / Barry Richards, Kenny Howard and StephenWilliams // Automated Fastening / Assembly & Tooling in Aerospace. – SAE International,2007. – P. 25-28.

4. Kihlman Henrik. Flexible Fixtures with Low Cost and Short Lead-Times / Henrik Kihlman andMagnus Engstrom // Automated Fastening / Assembly & Tooling in Aerospace. – SAEInternational, 2007. – P. 29-36.

5. Olazagoitia Jose Luis. New PKM Tricept T9000 and its Application to Flexible Manufacturingat Aerospace Industry / Jose Luis Olazagoitia and Scoott Wyatt // Automated Fastening/ Assembly & Tooling in Aerospace. – SAE International, 2007. – P. 37-48.

6. Buckingham Rob. Snake-Arm Robots: A New Approach to Aircraft Assembly / BenoitMarguet, Vilas Chitrakaran, Rosalind Conkle, Geoff Ferguson, Andrew Graham, Alex Lazell,Mariusz Lichon, Nick Parry, Fred Pollard, Amir Kayani, Mike Redman, Mark Summers andBrett Green // Automated Fastening / Assembly & Tooling in Aerospace. – SAE International,2007. – P. 71-76.

7. Dillhoeler Thorsen. All Electric System (AEFS) / Thorsen Dillhoeler and Brian O'Rourke //Automated Fastening / Assembly & Tooling in Aerospace. – SAE International, 2007.– P. 1-10.

8. Техническое описание конвейерных линий сборки металлического крыла на заводе им.Сталина / НКАП СССР Научно-исследовательский институт технологии и организациипроизводства авиационной промышленности ОРГАВИАПРОМ. – Москва, 1945. - С. 28.

9. Метод автоматизированной конвейерной сборки планера самолета [Текст] / В.С.Кривцов, Ю.А. Воробьев, В.В. Воронько, В.Е. Зайцев // Открытые информационные икомпьютерные интегрированные технологии: Сб. науч. трудов. – Вып. 55.– Харьков: Нац. аэрокосмический ун-т «ХАИ», 2012. – С. 5 – 13.

10. Воронько, В.В. Формализация и алгоритмизация процессов сборки в самолетостроении[Текст] / В.В. Воронько, О.К. Погудина // Открытые информационные и компьютерные



интегрированные технологии: сб. науч. тр. Нац. аэрокосм. ун-та им. Н.Е. Жуковского«ХАИ». – Вып. 57. – Х., 2012. – С. 86 – 92.

11. Воронько, В.В. Концепция создания программного обеспечения для визуализациипроцессов сборки плоских узлов планера самолета [Текст] / В.В. Воронько//Авиационно-космическая техника и технология: сб. науч. тр. Нац. аэрокосм. ун-та им.Н.Е. Жуковского «ХАИ». – Вып. 2/99. – Х., 2013.

Prepared under the aegis of KhAI-ERA projectfunded by the European Commission’s Directorate-Generalfor Research & Innovations under the FP7 CapacitiesSpecific Programme on International CooperationGrant Agreement no 294311National Aerospace University

“KhAI”17 Chkalova str., Kharkiv

61070 Ukrainewww.khai.edu

Automated Assembly of Aircraft Structures -...

Documents

Transcript of Automated Assembly of Aircraft Structures -...