Improved Dynamic Positioning of High Speed Drilling Robots for Aerospace Composite Manufacturing

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Due to their versatility and large working volume, industrial robotic arms have been increasingly integrated into the aerospace industry to improve the efficiency and reliability of manufacturing operations. Boeing Winnipeg is the largest aerospace composite manufacturer in Canada producing complex fiberglass and carbon composite structures for Boeing Commercial Airplanes. Preparation of some of these composite structures involves drilling of large patterns of small holes, which is performed by a high speed robotic drilling system. During this operation, the robot must constantly undergo rapid acceleration and deceleration stages, which lead to excessive oscillations at the end-effector (tool holder). Tool vibrations result in geometric errors, poor hole quality, and possibly, violation of the required tolerance. This project aims at developing passive and active control techniques to suppress structural vibrations in high speed robotic drilling systems.The proposed research collaboration will result in systematic and scalable control techniques which enable robotic manufacturing systems to perform their operations at higher speeds with enhanced accuracy and reliability. In particular, the outcome of this project will help Boeing Canada Winnipeg to remain internationally competitive by providing them with fundamental knowledge, innovative technologies, and HQP training to enable them to increase their throughput, decrease cost and lead times, improve part quality, and ultimately, enhance the reliability, safety, and cost-efficiency of airplanes.