High accuracy robotic digital twinning

In the aerostructure assembly domain, manufacturers are looking for a solution for high accuracy, intelligent assembly, at an affordable price.

The cost of bespoke automation and specialist machine tools is prohibitively high, for most assemblies. This has led to a focus on the use of robotics. These machines are widely used in other industries, with competitive prices and proven reliability.

But robots are not built for really high accuracy, with many assemblies having higher build tolerances than the machines themselves. Most processes are also not built on “repeatability” but require “intelligence” to manage complex assembly requirements, such as flushness with components of variable thickness (particularly composites).

Add into the mix, the desire to create those robot programs in a virtual environment, in a low-rate manufacturing plant. The goal to “run” without human intervention negating “touch-up” and “commissioning” programs.

This presentation is an open technical discussion of the challenges we have faced in robotic direct digital twinning to 0.1mm +/= 3 sigma (99.7% confidence) in aerostructure assembly.

The format is: -
• An introduction to robotics and sources of error – for those new to the art
• The digital twinning requirements to create a successful Off-Line generated robot programs
• The sensor technology on the shop floor
o To provide a high volumetric accuracy working space
o To guide the real robot to its virtual twin, within this space
o The “Intelligence” to manage build variation successfully
o The “intelligence” to manage compliance within the robot when “clamping-up” and preventing robot tool movement on the part

The objective is to share knowledge, for the wider adoption of robotics, successfully, in aerostructure assembly.