Simulator proves DTI’s Airbus advanced automated wing production manufacturing method

Simulation software from Tecnomatix was instrumental in the success of the now complete second phase of Airbus UK’s Automatic Wing Box Assembly two year research project (AWBA II), funded by the DTI to improve production methods for large precision structures. AWBA was launched to identify and acquire technologies to automate assembly of large wings: it integrates, for the first time, everything from handling, to positioning, measuring, robotic drilling, wing skin panel wrapping and fastening technologies in a single 8.5 metre high demonstrator. Software from Tecnomaitx’s eMPower range was used by RTS Advanced Robotics and BAE Systems Advanced Technology Centre at Sowerby to simulate robot options and provide off-line programming. It was also used for systems integration and for 3D manufacturing cell modelling by Airbus and its partners. It meant the design team was able to simulate component interaction and thus validate ideas before committing to manufacture. Stephen Giles, Teconmatix’s sales manager, says it’s proven the power of simulation in moving rapidly from concept to reality. It’s also demonstrated company’s scope of software and services – Tecnomatix was responsible for producing a complete cell demonstrator simulation using data models from each of the project partners – and then bulding a full-scale production mock-up for the wing box. Giles: “As well as supporting the project, this underlines the crucial role of Tecnomatix’s eMPower simulation model in providing the only means for linking research activity with the eventual possibility of applying the ideas to an actual production environment.” And beyond that there are clear implications for much of design for manufacture: simulation of this kind does provide an excellent virtual test bench for any programme involving building precision structures. One example in the AWBA II programme was simulation used to investigate and define a measurement strategy based on lasers and line of sight targets within the tooling framework. The partners say it was a simple matter to configure an application module to link BAe Systems measurement system right into the simulation test bed.