Towards Industry 4.0: The Future Automated Aircraft Assembly Demonstrator

As part of the Future Automated Aircraft Assembly Demonstrator developed by the University of Nottingham, this paper presents a new flexible production environment for the complete manufacturing of high-accuracy high-complexity low-volume aerospace products. The aim is to design a product-independent manufacturing and assembly system that can react to fluctuating product specifications and demands through self-reconfiguration. This environment features a flexible, holistic, and context-aware solution that includes automated positioning, drilling and fastening processes, and is suitable for different aircraft structures with scope to address other manufacturing domains in the future (e.g. automotive, naval and energy). The assembly cell features industrial robots for the handling of aircraft components, while intelligent metrology and control systems monitor the cell to ensure that the assembly process is safe and the target tolerances are met. These three modules are integrated into a single standardized interface, requiring only one operator to control the cell. Performance analyses have shown that, using the reconfigurable production environment described hereafter, a positioning accuracy better than ±0.1 mm can be achieved for large airframe components.