WINBOXTOOL is a CleanSky H2020 project which have been recently finished, which also accounts with the participation of Itainnova.
This project has developed a versatile prototype tooling set (80% of the tooling) for the cost efficiency assembly and transport of the morphing winglet and multifunctional outer flaps of the next generation optimized wing box (reduction of 15% in time and 10% in cost).
This innovative approach, based on the utilisation of a fully automated all-in-one machine and additive manufacturing technologies, eliminates the effect of most of the errors and geometrical deviations in the tooling production and assembling processes due to the implementation of a single and fully controlled working environment.
The project has achieved the following key objectives:
1) Its ability to keep high-accuracy and permanent tracking in vast areas by means of a laser tracker application. This targets the assembly of medium and large components and solves a recurring problem in the aeronautics, building and aerospace industries (cumulative assembly errors and lack of accuracy in the final stages of the assembly process).
2) Its ability to make highly accurate assembly holes (TCs) using robotics, to track and correct the positioning process in real-time, and to transport the assembly tool safely.
This targets the positioning of medium and large components and solves another recurring problem in the aeronautics, building and aerospace industries (traditionally, new parts are designed and attached to the main frame and thus several errors happen intrinsically: (1) the tolerance is affected by the precision of the milling machine and (2) inaccuracies happen when positioning the jigs on the frame).
3) Its ability to use automated processes, based on human guidance, instead of traditional manual processes. Without WINBOXTOOL, the assembly operations usually include a number of error-adding manual processes (e.g. transferring holes from a reference part to its subsequent part) that are done by the operator, sometimes carrying tools heavier than 5 Kg and using them in rather poor positions, ergonomics-wise.
José Antonio Dieste, project coordinator highlighted one of the over expected achievements:
"We are very proud of being able to keep high-accuracy and permanent tracking in vast areas by integrating redundant reflectors in the robotic cell and reflectors on the surface of the own prototype tooling set, and working with those using the same laser tracker base, a full CAD of the machine-assembly tool group can be done, thus obtaining a fully synchronized manufacturing base for the prototype assembly production and for the manufacturing of the assembly tool."
This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 737889.