Finding the missing link

The manufacture of large fabricated metal structures poses a number of significant problems, particularly when attempts are made to automate the process. This article describes some new techniques that are being developed to solve many of these problems, thereby opening up the possibility of automating the assembly of many products such as aircraft, transportation systems or large pre-fabricated structures. One of these techniques combines simulation based control with non-contact metrology, mathematical modeling and innovative robot end-effectors to provide practical solution and allow the effective and safe use of industrial robots within a partially defined environment. Using this technique, a working demonstrator cell was developed and is being evaluated using fuselage components from the Canadair CRJ700 regional jet. The system has been developed primarily for use in the manufacture of airframes but the technique is applicable to any structures that are liable to deformation during assembly.