Jig-less end-effector system for automating exhausting composite fuselage assembly tasks
Collections: Brunel Composite Centre ; In this study, the jig-less end-effector system developed to assemble components of a full-scale multifunctional integrated composite thermoplastic lower fuselage section is tested and validated. To offset the environmental impact of higher volume of air transport, the aviation industry wants to design lighter and more environmentally friendly aircraft. To achieve this, there is a need to exploit novel materials and technologies. Advanced thermoplastic composites provide an excellent material option thanks to their weldability, low density, low overall production cost, improved fracture toughness and recyclability. However, to fully appreciate their capabilities and benefits, new manufacturing approaches and techniques are needed. Hence, projects such as TCTool, "innovative tooling, end-effector development and industrialisation for welding of thermoplastic components", aim to develop innovative tooling and end-effector systems for the assembly of a multifunctional thermoplastic fuselage. This study presents the development, operation, and testing of the jig-less end-effector system used in the TCTool project for picking, placing, and temporary welding and fixing fuselage's clips and stringers. ; This study has received funding from the Clean Sky 2 Joint Undertaking under the European Union's Horizon 2020 research and innovation program under grant agreement No. 865131 for TCTool Project, and has been partially funded by the projet "5R – Cervera Network in robotic technologies for intelligent manufacturing", contract number CER-20211007, under "Centros Tecnológicos de Excelencia Cervera" (founded by "The Centre for the Development of Industrial Technology (CDTI)"). The authors would like to thank TWI Ltd. for conducting the tensile tests and optical microscopy. TCTool project partners: GKN-Fokker Aerospace, TWI Ltd., Andalusian Foundation for Aerospace Development – Advanced Center for Aerospace Technologies, Brunel University London, London South Bank University, Acroflight Ltd.