Development trend of industrial robots in aerospace manufacturing

In recent years, industrial robots have been widely used in many industries such as automobile, electronics, food, chemical, and logistics due to their high repeatability, reliability, and applicability, effectively improving product quality and production efficiency. It saves labor and manufacturing costs, enhances production flexibility and corporate competitiveness. In addition, it plays a very important role in ensuring personal safety, improving the working environment, reducing labor intensity and reducing material consumption. At present, the aerospace product manufacturing process is still labor intensive, complicated in process, poor working conditions, supplemented by a large number of fixtures and hand-made. Insufficient automation production capacity has become a bottleneck restricting the reliability and production capacity of weapons and equipment. Under the background of China's vigorous development of aerospace, aerospace manufacturing enterprises use industrial robots for automated production, which is of great significance and value for the transformation and upgrading of production models and the improvement of advanced manufacturing capabilities.

In the field of aerospace manufacturing, industrial robots not only perform typical dispensing, welding, spraying, heat treatment, handling, assembly and testing operations, but also drill, riveting, sealing, trimming, composite coating, non-destructive testing, etc. Special job tasks. Unlike traditional manufacturing industries, aerospace products are characterized by large size, complex structure, high performance index accuracy, heavy load, high environmental cleanliness and special materials. The structure, performance, process flow and reliability of industrial robots are all Put forward higher requirements. In addition, the multi-variety and small-batch production characteristics of aerospace products also require industrial robots to have good work flexibility and scalability. Through rapid reconstruction, robot systems can be formed to adapt to new environments and new tasks.

Development at home and abroad

In response to the special needs of the industry, foreign industrial robot companies and aerospace manufacturing companies have cooperated closely to develop special industrial robot systems for components assembly and human-machine cooperation to enhance the competitiveness of enterprises. At the end of 2012, under the support of the EU's Seventh Framework Programme (FP7) “Future Factory” project, Germany, Austria, Spain and other countries jointly launched the VALERI project, which aims to achieve advanced robot recognition and human-machine collaboration within three years. Integrated into the production of aerospace components, the robot can work directly with people, eliminate the protective isolation between man and machine, free people from simple and boring work, and then engage in more value-added work. The participating units include the Fraunhofer Institute for Industrial Operations and Automation, KUKA Laboratories, FACC, Profactor, IDPSA, PRODINTEC, Airbus and other aerospace and robotics research and manufacturing companies. The British Composites Center NCC and GKN and other aerospace companies have invested $4 million to develop a dual-mechanical automatic fiber placement system that not only saves material compared to manual work, but also replaces gantry-type tooling, reducing investment costs. In addition, manufacturing companies in the United States, Canada, Japan and other countries have also invested heavily in the development of industrial robot systems for aerospace manufacturing.

Since the 21st century, a large number of domestic enterprises have begun to independently develop or cooperate with research institutes to develop industrial robots and have entered the stage of initial industrialization [3]. However, in terms of overall technology, there is still a big gap between China's industrial robots and foreign advanced levels, which is only equivalent to the level of foreign countries in the mid-1990s. Due to the constant import of key unit components and devices such as high-performance AC servo motors and high-precision reducers , the cost of industrial robots in China remains high. Sweden's ABB, Japan's FANUC, YASKAWA, MOTOMAN, Germany's KUKA, the United States' AdeptTechnology, Italy's COMAU and other brands of industrial robots account for 90% of China's application market. Affected by this, the development of special industrial robot systems for the manufacture and assembly of aerospace products in China has just begun, and there is no scale and complete types.

Although China's industrial robot technology and products have been gradually applied and promoted in the assembly of aerospace components, aerospace products and satellite products, it still faces great challenges compared with the development of foreign technology. This paper analyzes and combs the research progress and development trend of industrial robot technology in aerospace manufacturing field at home and abroad in recent years, discusses its technical needs in non-traditional manufacturing fields and the key technologies that China's industrial robot technology research needs to solve in this field.

Technical needs analysis

1 mobile industrial robot

Industrial robots, which are widely used in the automotive, electronics, and food industries, are usually manufactured for small and medium-sized products, and will face enormous challenges in the manufacturing of large-scale products such as aviation, ships, and wind turbines. If the industrial robot system is scaled up, its manufacturing and control costs will be very expensive. In addition, aerospace large-scale products are often inconvenient to move during the manufacturing process. The solution of using dedicated, fixed-base industrial robots is not economical. Therefore, mobile industrial robots have become a new approach. Compared with traditional industrial robots, the same mobile industrial robot can perform the same work tasks in different positions, and the required programming time is shorter, which can improve the working efficiency and flexibility of the robot.

A typical configuration of a mobile industrial robot for large-scale product manufacturing is to mount an industrial robot system on a moving rail. Depending on the installation location, the structure can be divided into gantry type (Fig. 1(a)) and ground track type (Fig. 1(b)).

The accuracy of an industrial robot is determined by the accumulation of all joint and link errors between the ground reference system and the end effector. Orbital configuration is often plagued by work loads and structural forces, causing structural deformation and further affecting machining accuracy. Track deformation is random, and it also causes great difficulty in compensating for positional accuracy. In addition, the track structure will occupy a large work space and the ground, increasing the cost of plant investment and maintenance.

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