Challenges facing FAUB in aircraft manufacture
Background
FAUB – otherwise known as fuselage automated upright build, was implemented by Boeing in 2015, with the intended benefit of improving workplace safety and product quality. It relied on robots working in tandem to drill holes precisely and fasten together metal panels held upright to create the outer frame of the hulking twin-engine 777 jetliners. However, four years on, Boeing decided to move away from FAUB, and shift to a human-plus-machine approach following reliability and rework issues.
A spokesman for Boeing in 2019 is on file as saying that the revised solution ‘has proven more reliable, requiring less work by hand and less rework, than the robots were capable of’.
However, while manufacturers may have found cases where technology can’t match the dexterity, creativity and precision of human hands and eyes in the past, solutions addressing these issues are now available.
Addressing FAUB issues
INSPHERE’s ORA adaptive robot control software facilitates incredibly precise, constantly monitored and immediately corrected robot activity – providing process reliability far outreaching that which was previously achievable.
ORA tracks robot movements and fixture alignment, generating in-depth data that can be compared to the program or simulation in use. Using this data, robot processes can be instantly updated without manual intervention, correcting for misalignment, inaccuracies and process variation errors.
And while this data allows for in-process robot cell adjustments, it also provides insights to assist with production planning for optimum output – further enhancing efficiencies.
Adaptable and flexible
Originally designed to work with INSPHERE’s robot measurement and tracking hardware IONA, continual investment is made into the development of ORA robot control software, and it now has the flexibility and adaptability to work with different robot brands and sensing systems, including laser trackers.
Allowing the user control over robot cell activity in-process makes management of the robot cell easier and more convenient than ever. This all means real-time updates occur, with minimal process interruption and material waste. Overall, process efficiency is massively improved.
Filling the skills gap
With aerospace manufacturing facing a talent crisis as older, experienced workers retire and the demand for skills continually grows, there is a shortage of people to fill specialist roles, resulting in production challenges. ORA precision robot control software could be the solution the aviation industry needs to address these issues.
