Aeronautics production of large composite wings

Before the MASTERLY Project: The assembly line of an aircraft center wing box involves several stations aided by an AGV and a robotic station, and the handling of the elements is performed using a bridge crane driven by operators. However, this operation is prone to swinging and could lead to damage to the components. A fine positioning of the elements is required to ensure the right match and avoid quality defects and errors in the assembly process. The fixtures used have an arch architecture and are formed by modular elements to adapt to different components, ensuring the quality of the final product.

With the MASTERLY solution: The production case will use a sensor network that will monitor the operations to reduce collisions and swinging, while an intelligent fixture with smart modules and metrology tools will enable fine positioning of the elements to be assembled, minimizing errors and deformation. The goal is to improve production rate, handling security, and final product quality.

Overview of AERNNOVA's Use Case Status and Key Milestones after 1 Year in the MASTERLY Project:

Over the past year, the AERNNOVA use case has focused on enhancing the assembly process for large aircraft structures, coordinated by a master PLC system that integrates robots, AGVs, and safety protocols for operators. The MASTERLY project has been instrumental in automating solutions for handling and lifting large panels, including accurate placement into assembly jigs, collision-free operation, load control, and damage prevention.

Key Achievements and Milestones:

• Takt Line Setup: This phase involved defining AERNNOVA’s assembly line, with in-depth analysis, documentation, and information sharing to guide the project’s tasks. A critical meeting held in April provided partners with real-world insights into the assembly process and its complexity, documented in deliverable 1.1 of WP1.
• Loading & Unloading Layouts: Initial steps focused on establishing an efficient layout for the safe loading and unloading of panels, setting the groundwork for seamless automation.

Challenges and Solutions:

1. Work Area Perception: Complex environments with operators, tools, and cranes necessitated advanced AI-powered perception for real-time collision avoidance.
2. Sensorization of Assembly Jig Parts: Accurate placement demanded integration of strain gauges in locating pins, enabling precise load monitoring and stress management during assembly.
3. Precise Panel Positioning: Positioning large panels with heavy-duty cranes was achieved with AI-assisted vision systems, ensuring fine control and precise alignment.

For more details on the AERNNOVA use case, please visit: AERNNOVA Use Case