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High versatility and accurate tooling set produced in All-In-One machine for the cost efficiency Sub-Assembly, Functional Checks and Transport of the Morphing Winglet and Multifunctional Outer flaps.

Periodic Reporting for period 2 - WINBOXTOOL (High versatility and accurate tooling set produced in All-In-One machine for the cost efficiency Sub-Assembly, Functional Checks and Transport of the Morphing Winglet and Multifunctional Outer flaps.)

Okres sprawozdawczy: 2018-07-01 do 2019-06-30

WINBOXTOOL develops a versatile prototype tooling set for the cost efficiency Assembly and Transport of the Morphing Winglet and Multifunctional Outer Flaps of the next generation optimized wing box. The proposed innovative approach, based on the utilisation of a fully automated all-in-one machine and additive manufacturing technologies, eliminates the effect of most errors and geometrical deviations in the tooling production and assembling processes due to the implementation of a single and fully controlled working environment.

The potential impact of WINBOXTOOL resides on three key pillars:
• Its ability to keep high-accuracy and permanent tracking in vast areas by means of a laser tracker application. This targets the assembly of medium and large components and solves a recurring problem in the aeronautics, building and aerospace industries (cumulative assembly errors and lack of accuracy in the final stages of the assembly process).
• Its ability to make highly accurate assembly holes (TCs) using MEGAROB, to track and correct the positioning process in real-time, and to transport the assembly tool safely. This targets the positioning of medium and large components and solves another recurring problem in the aeronautics, building and aerospace industries (traditionally, new parts are designed and attached to the main frame and thus several errors happen intrinsically: (1) the tolerance is affected by the precision of the milling machine and (2) inaccuracies happen when positioning the jigs on the frame).
• Its ability to use automated processes, based on human guidance, instead of traditional manual processes. Without WINBOXTOOL, the assembly operations usually include a number of error-adding manual processes (e.g. transferring holes from a reference part to its subsequent part) that are done by the operator, sometimes carrying tools heavier than 5 Kg and using them in rather poor positions, ergonomics-wise.
In the technical workpackages, AITIIP started in the first period by collecting information about how the build sequence should be developed in each component. Morphing winglet assembling tooling, morphing winglet sub-assembling tooling, flap assembling tooling, flap sub-assembling tooling, transportation tooling and secondary tooling. AITIIP in collaboration with the Topic Manager (AERNNOVA) also underlined a realistic plan for evaluating, validating and verifying the technologies used during the project. These technologies lead the innovations of the WINBOXTOOL project. Around M6, a report including captions of the CAD design and validating reports for each design was built. At that point, due to delays, and always after approval of the Topic Manager, the fabrication of non-critical parts started (main structures). Later on, the consortium produced a report that included the validation of the technologies integrated on the innovation plan report. Around M8, the tooling design was almost complete. A report with captions of the CAD design, and the validating report for each design was written. By the beginning of the second period, as of M19, the status of the CDR specifications was only partial, but direct agreement with the relevant representatives of AERNNOVA allowed the consortium partners, and especially AITIIP, to start acquiring materials and to start the manufacturing partial processes. The full PDR for the entire set of WINBOXTOOL designs was released in November 2018. Manufacturing was resumed. The former agreement between TM and AITIIP concerning the partial CDR specifications helped the latter deliver all the remaining WP2 and WP3 reports and demonstrators in record time. The following key exploitable RESULTS were identified:
o Automated and controlled full assembly cell
o Lightweight dummy tools and processes for creating human guided processing paths
o Consultancy services (design, manufacture and assembly guidelines)
Their unique selling point lays on their abilities when it comes to reduction in cost, time and health risks for the operator; their potential for highly accurate assembly of medium and large parts and their easy adaptation in a crane robot cell. Different dissemination and communication materials have been delivered and presented in events of such importance as MetalMadrid2018, EU Industry Days 2018, AMEF 2018 and Advanced Factories during the project.
WINBOXTOOL is able to keep high-accuracy and permanent tracking in vast areas by integrating redundant reflectors in the robotic cell and reflectors on the surface of the own prototype tooling set, and working with those using the same laser tracker base, a full CAD of the machine-assembly tool group can be done, thus obtaining a fully synchronized manufacturing base for the prototype assembly production and for the manufacturing of the assembly tool.

WINBOXTOOL is also able to make highly accurate assembly holes (TCs) using MEGAROB, to track and correct the positioning process in real-time, and to transport the assembly tool safely. This is accomplished by the following:
o MEGAROB drills with a feed rate lesser than 5mm per second and has shown a positioning error of the robot TCP under 50 microns
o MEGAROB features a high-accuracy tool changer system that allows assembling any kind of device on the robot TCP (plus the aforementioned drill and the welding torch). A pneumatic “zero point” system is located on the flange of the robot with a female connector that ensures 6DoF tool holding. All the tools to be assembled will have the male end of the connector. This will ensure a tool assembly repeatability under 5 micrometers and a pulldown force up to 1500N. During the manufacturing of the tooling set:
1. The robot seizes each tool, and the fixed TCs jig are mounted and clamped in position.
2. The robot takes the tool to the final position, always real-time guided and monitored, with error values under 50 microns.
3. The robot stops at the final destination and the tool is welded or fixed to the main structure with epoxy resin material.

WINBOXTOOL also has the ability to use automated processes, based on human guidance, instead of traditional manual processes. The way WINBOXTOOL turns this problem into a strength is by:
o Designing and additively manufacturing lightweight dummy tools equipped with 6DoF position sensors. These will be used to teach the exact positions to the machine, where holes have to be done or processes need to be carried out.
o The laser tracker monitors the exact position and orientation of the tool as the operator simulates the places where holes have to be drilled.
o The dataset containing the XYZ points and trajectories of the dummy tool will be recorded. After the operator finishes describing the guiding paths, the robot will proceed to do the actual work, drilling all the holes in position and using the real-time correction algorithms developed for MEGAROB.
Accepted tooling at the TM premises