Future Automated Aircraft Assembly Demonstrator (ITT/653).

Descriptions

To support the growing portfolio of research projects at the Centre for Aerospace Manufacturing (CAM) the University of Nottingham is making a strategic capability investment in the area of advanced informatics-enabled manufacturing. The aim is to develop a unique new research demonstrator of future automated aircraft assembly processes and systems. The demonstrator will have the capability to assemble at least 2 different aerospace products with scope to address other manufacturing domains in the future such as automotive, naval and energy.The scope of the research demonstrator has been defined in a partnership with strategic global industrial partners including Airbus, BAE Systems, GE Aviation and GKN. The demonstrator will be specifically focused on future reconfigurable assembly systems including automated drilling, bonding and fastening processes, highly flexible and adaptable tooling and fixtures and analytical data intensive component and process tracking and validation.The research demonstrator will include as a minimum the following key elements:A.Demonstrator IT InfrastructureThe demonstrator IT infrastructure consisting of Portal Interface, Component Data Monitor, is required to integrate robotic, human and tooling elements and provide key functions such as control, monitoring, communication, data processing and performance monitoring.B.Data Capture, Position Monitoring and Inspection Infrastructure1 of the critical components in the demonstrator is the data capture, monitoring and communication infrastructure. The required equipment includes novel devices to provide capability for accurate position tracking and measurement, and the means to present this to relevant users.C.Tooling SetA selection of robot tools and auxiliary equipment has been requested to support a variety of applications ranging from drilling and machining heads to sealant dispensers and grippers.D.Robotic EquipmentRelevant robotics equipment will be integrated within the overall process and informatics infrastructure to deliver highly adaptive processes with enhanced precision and reliability. A carefully selected set of robots will be required to provide the capability to test new robotic concepts in cooperation, data exchange, human — robot interactions and hybrid decision making, teleportation, plug and produce integration, social learning, configuration and adaptation.Priority will be given to solutions offering next generation equipment that can demonstrate significant step changes in technology. As a guide the budget for Phase 1 of the Future Automated Aircraft Assembly Demonstrator is circa GBP 1 000 000.Tenderers are invited to bid for all work packages (e.g. WP1, 2, 3, 4, 5 and 6), individual work packages (e.g. WP 2) or any number of sub-work packages (e.g. WP1.2).19 (nineteen) of the total 27 (twenty-seven ) sub-work packages (Phase 1) will be awarded now (subject to affordability limitations) and the remaining 8 sub-work packages are intended to be awarded subject to further funding availability (Phase 2) at least circa. 12+ months. Nominations for preferred vendors (and reserve supplier in some cases) will all be announced now but subject to final contract and funding. Bid offers for phase 2 sub-work packages are required now and to be firm with any offer conditions/variances envisaged beyond 12 months clearly identified and where appropriate referenced/ indexed. However, should current funding afford any of these phase 2 sub-work packages now then some or all of these may be contracted in phase 1.Phase 1 sub-work packages: 1.1 and 1.3, 2.1/2/3/4/5/6, 4.1 and 4.2, 5.1/2/3 and 6.1/2/3/4/5/6Phase 2 sub-work packages (subject to current affordability/additional funding): 1.2, 3.1/2/3/4/5/6 and 5.4.Summary of Work PackagesWork Package WP#1: Assembly Fixtures and Automatic Guided VehicleSupply of assembly fixtures and Automatic Guided Vehicle for use with Product 1 and Product 2. This work package covers the supply of the Main Assembly Fixtures (MAF) required to hold the Wing Flap Component (Fixture 1) and Fuselage Component (Fixture 2) during assembly. The fixtures must be designed to move between Assembly Cell 1 and Assembly Cell 2 along with corresponding kitting racks. In addition the work package covers the supply of an Automatic Guided Vehicle (AGV) along with cassette or pallets to enable all parts necessary to build the Wing Flap Component or Fuselage Component to be delivered to the assembly cells in kit form.Sub-WP 1.1: Supplying and installing the Wing Flap Component Fixture (Fixture 1), associated kitting rack and track or other method of moving Fixture 1 between Assembly Cell 1 and Assembly Cell 2 (Phase #1).Sub-WP 1.2: Supplying and installing the Fuselage Component Fixture (Fixture 2), associated kitting rack and track or other method of moving Fixture 1 between Assembly Cell 1 and Assembly Cell 2 (Phase #2).Sub-WP 1.3: Supplying and installing an Automatic Guided Vehicle (AGV) system for transporting kits of parts to the Assembly Cell 1 and Assembly Cell 2 from the component storage area (Phase #1).Work Package WP#2: Robotic Drilling, Sealant and Fastener System for Assembly Cell 1Supply of robotic drilling and sealant and fastener end effector and installation in Assembly Cell 1. This work package covers the supply and installation of a cell (Assembly Cell 1) consisting of 2 robots each able to reach anywhere within the holding frames of Fixture 1 and Fixture 2. The robots will be used to drill holes in Al, Ti, CF and with any necessary Countersinking. In the case of Assembly Cell 1 one of the robots will be required to insert and correctly torque tighten Single Sided Slave Fasteners (SSSF). Sub-WP 2.1: Supplying and installing 2 robots capable of handling components and end effectors of up to 100 kg. Positional accuracy should be better than ±0.250 mm. Costs to include controller, pendant, drive modules and any necessary software (Phase #1).Sub-WP 2.2: Supplying and installing a tool changer for Robot 1. The tool changer should provide power, vacuum, pneumatics, sealant and fasteners to the end effector utilising plug and play (Phase #1).Sub-WP 2.3: Supplying and installing an end effector for Robot 1 consisting of a drilling head (Al and Ti) with programmable feeds and speeds with integrated single sided fastener insertion tool and metallic chip evacuation (Phase #1).Sub-WP 2.4: Supplying and installing a CF dust evacuation solution Sound Protection (Phase #1).Sub-WP 2.5: Supplying and installing an end effector for Robot 1 consisting of a sealant applicator, hoses, pumps and two part mix capability (Phase #1).Sub-WP 2.6: Supplying an end effector for Robot 2 for installing and torque tightening SSTF nut. (Phase #1).Work Package WP#3: Robotic Drilling, Sealant and Fastener System for Assembly Cell 2Supply of robotic drilling and fastener and rivet insertion end effector installation in Assembly Cell 2. This work package covers the supply and installation of a cell (Assembly Cell 2) consisting of two robots each able to reach anywhere within the holding frames of Fixture 1 and Fixture 2. The robots will be used to drill holes in Al, Ti, CF and with any necessary Countersinking. Assembly Cell 2 is for final fastening of the assembly and the removal of temporary fasteners (SSSFs). As such the robots should be capable of pushing together so as to create a force high enough to squeeze a rivet. To this end the minimum combined compressive force of the two robots at the edge of their reach envelope should be a minimum 1000Kg.Sub-WP 3.1: Supplying and installing two robots capable of handling components and end effectors of up to 1000Kg. Positional accuracy should be better than ±0.250mm. Costs to include controller, pendant, drive modules and any necessary software (Phase #2).Sub-WP 3.2: Supplying and installing a tool changer for Robot 1. The tool changer should provide power, vacuum, pneumatics, sealant and fasteners to the end effector utilising plug and play (Phase #2).Sub-WP 3.3: Supplying and installing an end effector for Robot 1 consisting of a drilling head (Al and Ti) with programmable feeds and speeds with metallic chip evacuation(Phase #2).Sub-WP 3.4: Supplying and installing a CF dust evacuation solution and Sound Protection (Phase #2).Sub-WP 3.5: Supplying and installing an end effector for Robot 1 consisting of a sealant applicator, hoses, pumps and two part mix capability (Phase #2).Sub-WP 3.6: Supplying an end effector for Robot 2 for installing and torque tightening a SSTF nut (in the case of Robot 1 inserting a bolt) or locating and apply force to the tail of the rivet so as to form the rivet tail (in the case of Robot 1 inserting a rivet and holding it in place) (Phase #2).Work Package WP#4: Metrology and Machine VisionSupply of metrology and machine vision for integration with Assembly Cell 1 and Assembly Cell 2.This work package covers the supply and installation of a metrology and machine vision system for integration with Assembly Cell 1 and Assembly Cell 2 to work in conjunction with Fixture 1 and Fixture 2. The fixtures will have precision datum points at each corner to allow the robots to calibrate themselves to these positions. The robots will also require a non-contact measurement capability that will maintain positional accuracy to ±0.250mm.Sub-WP 4.1: Supplying and installation of a non-contact geometry inspection system for use with Cell 1 and Cell 2 for the automated and manual measurement of large-scale objects (Product 1 and Product 2) within a range of 40m. The system must be capable of being integrated with automated production tools (Phase #1).Sub-WP 4.2: Supplying and installation of a part inspection system / CMM for installation on Robot 1 in Cell 2. System must be capable of inspecting Aerospace Parts against CAD Drawings for Gap, Feature and Surface Inspection(Phase #1).Work Package WP#5: Informatics InfrastructureSupply of informatics infrastructure for integration with Assembly Cell 1 and Assembly Cell 2.This work package covers the supply and installation of an informatics infrastructure for integration with Assembly Cell 1 and Assembly Cell 2 for the control, tracking and auditing of component assembly of Product 1 and Product 2.Sub-WP 5.1: Supplying RFID (or similar) tags for installation on Fixture 1, Fixture 2, transportation system, kitting systems and Product 1 and Product 2 sub-components. The RFID should be rugged and adaptable with a 5 year battery life(Phase #1).Sub-WP 5.2: Supplying antennas and radio receivers (sensors) for calculating the location of tags within the demonstration area including Cell 1, Cell 2 and the material loading and unloading area. There should be enough sensors to determine accurate location from a single sensor and a precise 3D location to be determined when only two sensors receive the signal(Phase #1).Sub-WP 5.3: Supplying a control system and software for real-time location control using the above sensors systems (Phase #1).Sub-WP 5.4: Supplying a PC based server and software for data acquisition. (Phase #2).Work Package WP#6: Project Management, System Integration and CommissioningProject Management, System Integration and Commissioning of WP1, 2, 3, 4 and 5 within Assembly Cell 1 and Assembly Cell 2.This work package covers the supply and installation of the pneumatic, power and communications infrastructure required to integrate WP1, 2, 3, 4 and 5 into a working demonstrator system in order to provide a “turnkey system” to the university. This work package will include the supply of any further control systems, software integration and mechanical infrastructure in order to accomplish this and should be flexible enough to allow for additional and/or different robots to be either inserted or removed from the system (see Figure 11).Sub-WP 6.1: Supplying and installation of the pneumatic, power and communications infrastructure required to integrate WP1, 2, 3, 4 and 5 into a working demonstrator system. This will include networking of industrial computers per relevant robotic device for distributed autonomous control and monitoring e.g. TCIP, CAN bus and a wireless communication infrastructure(Phase #1).Sub-WP 6.2: Supplying and installation of a Maintenance Management System (MMS). A suitable MMS that is accepted in the aerospace industry (Phase #1).Sub-WP 6.3: Supplying and installation of cameras and associated software for selectively monitoring relevant processes(Phase #1).Sub-WP 6.4: Cost of project management of the complete solution including equipment specification and integration plan (Phase #1).Sub-WP 6.5: Cost of commissioning the complete solution including training of University of Nottingham staff (Phase #1).Sub-WP 6.6: Cost of CE marking the demonstrator. Tenderers for Assembly Cell 1 and Assembly Cell2 will provide fully safety files, risk analysis and / or CE Marking (Phase #1).ENDS.