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Title: Large volume metrology assisted production of aero-structures
Author: Wang, Zheng
Awarding Body: University of Bath
Current Institution: University of Bath
Date of Award: 2013
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The research presented in this thesis was carried out within the Large Volume Metrology group at the University of Bath. The main goal of the research study is to develop and demonstrate novel applications of integrated and automated metrology systems in aero- structure production, with a particular focus on the development. and capability assessment of real-time metrology integration. A survey through the relatively limited amount of literature on the state of the art of integrated and automated metrology showed some promising results. Encouraged by the positive results, studies were undertaken showing that many of the current aero-structure production issues involving measurement and data processing can be solved through better integration and automation of metrology systems. It was partially demonstrated that the health assessment of an entire wing jig could be carried out automatically within 13 minutes, compared to the traditional manual process which could takes many days. To better understand and quantify the capabilities and benefits of a hypothetical production system with integrated metrology, methods of mathematically simulating Metrology Assisted Assembly (MM) systems were developed, and tested in a number of application case studies. It was shown that MAA processes can be effectively simulated using the Monte Carlo method. The case studies showed that these simulations can provide critical insight and information of the processes to the decision makers. The practical implementations of rea l-time integration with metrology instruments, a key enabler of MAA, were then addressed, and software methods of interfacing directly with a number of instruments in real-time were developed and demonstrated. The potential application of real-time metrology in mobile robot navigation was also highlighted. Finally, building upon software instrument interfaces, a prototype 3-axis machine was constructed using Low cost off-the-shelf components in order to demonstrate the potentials of real-time MAA for manufacturing processes such as milling and drilling. Using a laser tracker to provide real-time error correction, it was possible to dramatically increase the positioning accuracy and repeatability of the machine. Using real-time feedback a 50% reduction in static repeatability and 40 to 140 times reduction in statc positioning errors were achieved.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available