Sensor-based precision robotic deburring for aerospace manufacturing

航空航天制造涉及大型复杂零件，具有高度可变性和严格的精度和可靠性限制。自动化制造可以提高质量和效率，同时降低对人类的风险。去毛刺是一个非常复杂、耗时且昂贵的过程，目前在该行业中手动完成。手工去毛刺高度依赖于人类技能，容易出错，并且与潜在有害灰尘的一致性低。金属板材加工中的机器人去毛刺需求很高，但由于涉及复杂的规划、严格的公差和可变的负载，因此实施起来非常复杂。该项目将卡尔顿大学的机器人专业知识与阿恩普赖尔航空航天公司（AAI），一个主要的安大略航空航天结构供应商，以全球飞机工业，开发基于传感器的精密机器人去毛刺（SPRD）技术的薄板金属零件。为了达到所需的加工稳定性和精度，各种多层传感器为基础的控制器将进行研究。一个开放式的实验平台，RoboDeb-E，将被设计和集成作为SPRD技术的概念验证。该平台有助于研究先进的传感，控制和数据处理方法，并使研究能够更好地了解材料去除过程和工艺参数之间的相互关系。这项研究包括一个系统的实验研究，量化的SPRD技术的性能和比较的结果，通过手工去毛刺工艺生产的零件质量由AAI机械师。该研究的结论是SPRD的工业版本RoboDeb-I的详细规格，以在AAI生产零件。RoboDeb-I将通过安大略卓越中心（VIP-II计划）的资金立即进行后续项目。虽然SPRD立即影响AAI的生产力，但它在其他部门或流程中具有很大的应用潜力。由此产生的系统可以促进制造和自动化科学，创造当地的高科技机会和经济效益，并有助于维持加拿大的航空航天制造业务及其作为主要飞机制造中心的声誉。

Aerospace manufacturing involves large and complex parts with high variability and stringent precision and reliability constraints. Automated manufacturing can improve quality and efficiency while reducing the risk to humans. Deburring is a very complex, time-consuming, and expensive process that is currently done manually in this sector. Hand deburring is highly reliant on human skills and is prone to errors and low consistency with potentially harmful dust. Robotic deburring in sheet metal working is in high demand, but very complex to implement due to the complex planning, tight tolerances, and variable loading involved. This project brings Carleton University's robotics expertise together with Arnprior Aerospace Inc (AAI), a major Ontario supplier of aerospace structures to aircraft industry worldwide, to develop a Sensor-based Precision Robotic Deburring (SPRD) technology for thin sheet metal parts. To achieve the required machining stability and precision, various multi-layer sensor-based controllers will be investigated. An open-architecture experimental platform, RoboDeb-E, will be designed and integrated as the proof-of-concept for the SPRD technology. This platform facilitates the research on advanced sensing, control, and data processing methods, and enables studies to gain a better understanding of the material removal process and inter-relation of the process parameters. This research includes a systematic experimental study to quantify the performance of SPRD technology and compare the results to the quality of parts produced via hand deburring process by AAI machinists. The research concludes with a detailed specification of an industrial version of SPRD, RoboDeb-I, to produce parts at AAI. RoboDeb-I will be developed through an immediate follow-on project through funds from Ontario Centres of Excellence (VIP-II program). While SPRD immediately impacts productivity at AAI, it has a great potential for application in other sectors or processes. The resulting system can boost manufacturing and automation science, generate local high-tech opportunities and economic benefits, and help maintaining aerospace manufacturing business in Canada and its reputation as a major aircraft manufacturing hub.