Welding end-effectors ready for demonstrator assembly

Abstract

This report deals with the overall description of the functionality of the developed and matured welding end-effectors as well as with the concept for automated control and the accompanying inline quality assurance for the upper test shell manufacturing. Ultrasonic spot welding, continuous ultrasonic welding and resistance welding can be named as applied welding technologies within the MFFD`s upper shell assembly. Customized welding end-effectors for the integration of stringers and cleats were designed and manufactured. Here special focus was set on the end-effectors for continuous ultrasonic welding (CUW) and cleat integration. The CUW end-effector underlies continuous improvements that are described later on. For cleat integration a series of two robots, a KUKA LBR with the attached cleat end-effector mounted on a KUKA KR270 was chosen as solution for the force- and torqueless cleat integration. Special focus was set on high flexibility of the assembly jigs and processes in order to overcome with the challenges of single part tolerances and its compensation during assembly. Skin manufacturing and the structure assembly is monitored by an integrated inline quality assurance system.