AGREED Süd – Automation for flexible and scalable skin assembly with digital intelligence

Project Goal and Robot Cell Setup

The aim of the AGREED Süd project was to automate the manual pre-assembly of aircraft skins in the aerospace industry. The research station was set up at Airbus in Augsburg and comprises a robot cell with two industrial robots, nine interchangeable end-effectors and a modular fixture for various skin panels. In collaboration with the DLR ZLP Augsburg, the end-effectors and processes were developed and implemented in the robot cell at Airbus.

Process: Pre-Treatment and Clip Detection

The process begins with the pre-treatment of skin panels and components: cleaning and activation are carried out using special end-effectors that feed liquids via a pump system and wipe the surfaces clean after the exposure time has elapsed. The clips are detected by a camera mounted on the robot; their position is recorded and a correction factor for gripping is calculated. The clips are gripped using 3D-printed inlays tailored to their individual geometry.

Assembly: Sealant, Rivets and Fixing

The two-component sealant is then precisely applied to the stringer surfaces. The stringers are picked up using a gripping and riveting tool; the rivets are positioned and automatically threaded into the pre-drilled holes with the aid of a camera system. Assembly is carried out synchronously by both robots; the rivets are set and the stringers are provisionally fixed in place. The clips, together with their inlays, are then picked up, coated with sealant and pressed against the skin panel. Pressure is applied autonomously via a force-torque control system that takes tolerances into account. The inlays contain magnets that hold the clip in place during the curing time.

Results and Outlook

The entire process chain – from pre-treatment to temporary fixing – was successfully completed in December 2021 during a live demonstration. The results demonstrate high process accuracy, a significant reduction in cycle time and a marked improvement in reproducibility compared with manual methods. The technologies are modular, scalable and represent a key building block for the future digital and automated manufacture of large aerospace structures.

Funding