In aircraft assembly, multiple laser trackers are used simultaneously to measure large-scale aircraft components. To combine the independent measurements, the transformation matrices between the laser trackers’ coordinate systems and the assembly coordinate system are calculated, by measuring the enhanced referring system (ERS) points. This article aims to understand the influence of the configuration of the ERS points that affect the transformation matrix errors, and then optimize the deployment of the ERS points to reduce the transformation matrix errors. To optimize the deployment of the ERS points, an explicit model is derived to estimate the transformation matrix errors. The estimation model is verified by the experiment implemented in the factory floor. Based on the proposed model, a group of sensitivity coefficients are derived to evaluate the quality of the configuration of the ERS points, and then several typical configurations of the ERS points are analyzed in detail with the sensitivity coefficients. Finally general guidance is established to instruct the deployment of the ERS points in the aspects of the layout, the volume size and the number of the ERS points, as well as the position and orientation of the assembly coordinate system.

Purpose: The purpose of this paper is to present an optimal posture evaluation model to control the assembly gaps in aircraft wing assembly. The gaps between two mating surfaces should be strictly controlled in precision manufacturing. Oversizing of gaps will decrease the dimensional accuracy and may reduce the fatigue life of a mechanical product. To reduce the gaps and keep them within tolerance, the relative posture (orientation and position) of two components should be optimized in the assembly process. Design/methodology/approach: Based on the step alignment strategy, i.e. preliminary alignment and refined alignment, the concept of a small posture transformation (SPT) is introduced. In the preliminary alignment, an initial posture is estimated by a set of auxiliary locating points, with which the components can be quickly aligned near each other. In the refined alignment, the assembly gaps are calculated and the formulation of the gaps with component posture is derived by the SPT. A comprehensive weighted minimization model with gap tolerance constraints is established for redistributing the gaps in multi-regions. Powell-Hestenes-Rockafellar optimization, Singular Value Decomposition and K-Dimensional tree searching are introduced for the solution of the optimal posture for localization. Findings: Using the SPT, the trigonometric posture transformation is linearized, which benefits the iterative solution process. Through the constrained model, overall gaps are minimized and excess gaps are controlled within tolerance. Practical implications: This method has been tested with simulated model data and real product data, the results of which have shown efficient coordination of mating components. Originality/value: This paper proposed an optimal posture evaluation method for minimizing the gaps between mating surfaces through component adjustments. This will promote the assembly automation and variation control in aircraft wing assembly.

To gain accurate support for large aircraft structures by ball joints in aircraft digital assembly, this paper aims to propose a novel approach based on visual servoing such that the positioner’s ball-socket can automatically and adaptively approach the ball-head fixed on the aircraft structures. Image moments of circular marker labeled on the ball-head are selected as visual features to control the three translational degrees of freedom (DOFs) of the positioner, where the composite Jacobian matrix is full rank. Kalman–Bucy filter is adopted for its online estimation, which makes the control scheme more flexible without system calibration. A combination of proportional control with sliding mode control is proposed to improve the system stability and compensate uncertainties of the system. The ball-socket can accurately and smoothly reach its desired position in a finite time (50 s). Positional deviations between the spherical centers of ball-head and ball-socket in the X-Y plane can be controlled within 0.05 mm which meets the design requirement. The proposed approach has been integrated into the pose alignment system. It has shown great potential to be widely applied in the leading support for large aircraft structures in aircraft digital assembly. An adaptive approach for accurate support of large aircraft structures is proposed, which possesses characteristics of high precision, high efficiency and excellent stability.

Purpose: This paper aims to provide a shimming method based on scanned data and finite element analysis (FEA) for a wing box assembly involving non-uniform gaps. The effort of the present work is to deal with gap compensation problem using hybrid shims composed of solid and liquid forms. Design/methodology/approach: First, the assembly gaps of the mating components are calculated based on the scanned surfaces. The local gap region is extracted by the seed point and region growth algorithm from the scattered point cloud. Second, with the constraints of hole margin, gap space and shim specification, the optional shimming schemes are designed by the exhaustive searching method. Finally, the three-dimensional model of the real component is reconstructed based on the reverse engineering techniques, such as section lines and sweeping. Using FEA software ABAQUS, the stress distribution and damage status of the joints under tensile load are obtained for optimal scheme selection. Findings: With the scanned mating surfaces, the non-uniform gaps are digitally evaluated with accurate measurement and good visualization. By filling the hybrid shims in the assembly gaps, the joint structures possess similar load capacity but stronger initial stiffness compared to the custom-shimmed structures. Practical implications: This method has been tested with the interface data of a wing tip, and the results have shown good efficiency and automation of the shimming process. Originality/value: The proposed method can decrease the manufacturing cost of shims, shorten the shimming process cycle and improve the assembly efficiency.

Purpose: This paper aims to propose a calibration model for kinematic parameters identification of serial robot to improve its positioning accuracy, which only requires position measurement of the end-effector. Design/methodology/approach: The proposed model is established based on local frame representation of the product of exponentials (local POE) formula, which integrates all kinematic errors into the twist coordinates errors; then they are identified with the tool frame’ position deviations simultaneously by an iterative least squares algorithm. Findings: To verify the effectiveness of the proposed method, extensive simulations and calibration experiments have been conducted on a 4DOF SCARA robot and a 5DOF drilling machine, respectively. The results indicate that the proposed model outperforms the existing model in convergence, accuracy, robustness and efficiency; fewer measurements are needed to gain an acceptable identification result. Practical implications: This calibration method has been applied to a variable-radius circumferential drilling machine. The machine’s positioning accuracy can be significantly improved from 11.153 initially to 0.301 mm, which is well in the tolerance (±0.5 mm) for fastener hole drilling in aircraft assembly. Originality/value: An accurate and efficient kinematic calibration model has been proposed, which satisfies the completeness, continuity and minimality requirements. Due to generality, this model can be widely used for serial robot kinematic calibration with any combination of revolute and prismatic joints.

This paper addresses the problem of stabilizing the machine at a pose specified by a reference image and four laser sensor readings. The system configuration combining monocular vision and laser pointers is applied for pose estimation of the end-effector as well as providing the control objective. Specific features are selected to reflect the pose of the end-effector in Cartesian space, and an adaptive controller is designed to implement the alignment between the end-effector and a stationary object for further assembly. The complete control scheme is assessed through simulations and experiments conducted on an automatic drilling and riveting system, the results demonstrate that the assembly task can be accomplished accurately and efficiently even with coarsely calibrated camera and laser pointers. Furthermore, decoupled results can be gained thanks to the selected features.