Green, Affordable, High Accuracy Robot Drilling and Countersinking


TPR have developed a lightweight, low energy (green) robotic drilling system. Targeted for affordable automation of aerostructure small assemblies (hole sizes up to 10mm). It was successfully demonstrated at Technology Readiness Level (TRL6) – this being the highest level of acceptance outside of a manufacturing site. The testing was on the ATI (Aircraft Technology Institute) and Innovate UK grant funded “ADI: Automated Drilling and Inspection” project, with technical oversight from Airbus, BAE Systems, GKN Aerospace and FANUC UK.

 

Watch this YouTube video to find out more & see it in action!


True Position Robotics

Here you can see the lightweight, low energy (green) robotic drilling system @ FANUC UK Open House Event


True Position Robotics

Digital Twin to reality


Specifications

  1. Low payload, low energy, concession-free (part of Net Zero manufacturing Strategy)
  2. Affordability as defined by achieving Return on Investment target price from Innovate UK project ADI: Automated Drilling and Inspection with key aerospace manufactures at positional accuracy and countersink control on small box aerostructures.
  3. Drill system
    1. High frequency, water cooled, vector controlled, spindle
    2. S6 Power (load/no-load cycles) = 5kW (6.6kW Pmax/5sec)
  • Automatic collet change (HSK ER16) – max drill diameter 10mm.
  1. Spindle chiller unit
  1. Clamp-up System (Patent 2593501)
    1. Countersink Control CpK 4.39; tolerance +/- 0.04mm.
    2. Servo controlled with live force feedback
  2. Controls cabinet (option to use 3rd party spindles)
    1. Frequency Controller and EtherCAT 3 programmed drill PLC
    2. Designed to connect to cell PLC or direct to robot.
  3. Metrology PC, Software, and hardware.
    1. ARC+ patent pending robot guidance with machine learning
    2. ProLink QC-Calc Statistical Process Control reporting
  • Position CpK 2.91; mean 0.053mm; tolerance 0.254 mm
  1. Creaform C-Track Elite tracker
    • Volume up to 16.6m3 per camera (max 4 cameras per set-up)
    • 025mm accuracy; 0.064mm volumetric accuracy (95% confidence limit)
  2. Connectivity
    1. TCP/IP, OPC-UA, Profinet, EtherCAT
  3. 0 Smart templates (to fit inside Siemens Product Lifecycle Management system – particularly to import into Process Simulate robot simulation).
    • We believe our customers will want to “touch” our products through virtual interfaces
  4. Options
    1. Tool changer
      • Option for full robotic tool change
    2. Robots
      • FANUC robots/cobots; KUKA; ABB, Siemens 840D
  • Services
    • Virtual manufacturing support
    • Off-line robot programming
    • Training, maintenance, and calibration services

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