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Most automated assembly systems currently in use in the aeronautical industry utilize ISO code to support assembly programming. However, ISO code which serves a valuable function for NC milling machines, has a number or drawbacks when applied to assembly process including: Post processors are machine dependent, requiring significant reprogramming to accommodate elemental cell configuration differences or changes. ISO code is not user-friendly Programming modifications demand programming expertise, are beyond the capabilities of the machine operator, and are tedious and time consuming. The lack of program structure leads to difficulties in comprehension for operators. Then, in order to reduce programmer work and to simplify and secure operator interface, the CTRI Robotics Division of DASSAULT-AVIATION decided to design PEGASUS environment which offers powerful programming, cell control features and user-friendly Man-Machine Interface.

The goal of this paper is to present an innovative yet practical approach to automated aircraft assembly which meets the evolving aerospace industry requirements for flexibility and modularity. Adaptive Robotized Multifunction Assembly cell -ARMA is then described in two different vantage points: as a concept: a description of the philosophy which led to the development of automated assembly cells is offered as a practical solution: a description of the modular hardware and the powerful information processing system, that supports the individual cells is provided. The configuration which results in the most productive and effective cell while keeping the cost of equipment as low as possible is described. The ability of the cell to adapt to new requirements, as they evolve, is also described.

The Flexible Assembly Cell for Aeronautical Industry (FACAI) is described. The cell was developed in order to take advantage of the benefit of hard automation while retaining the flexibility of the manual assembly system it replaces. A description of both the generic equipment, selected to be non-specific to both the process and the assemblies intended to be built, is provided. In addition, all specific hardware, including end-effectors and fastener distribution systems are described, along with the rationale for their choice. The reasons for the modular design are explained. The means by which the flexibility goal was achieved are outlined. The demonstrated ability of the cell to install a wide range of fasteners (solid rivets, lockbolts, Hilocks) without the need for manual reconfiguration is detailed. The means by which both the quality and safety goals were attained are explained.

A unique “light” robot assembly cell, designed by the CTRI robotic division of DASSAULT AVIATION has been put in production in DASSAULT's Biarritz assembly plant. The designation “light” was chosen because it represents an alternative to either a heavy single purpose machine or a stiffer robotic system. The choice was made after a careful examination of the alternatives available and was based on the following hypothesis: a robotic cell, whose cost needs to be justified against a sub-contract opportunity of limited duration, must embody the following characteristics: 1) LOW COST in order to assure pay-back with the term of the subcontract 2) FLEXIBLE in order to accommodate future production requirements without major system modification. In order to meet these goals, we chose a standard low mass robot and provided it with a long track in order that it be able to cover a large work area at a minimum cost. The result was a very cost effective and efficient production system.