EMBRAER: Shear clip drilling and inspection cell
Software
In EMBRAER Botucatu, Brazil
Challenge to be solved
- Automatic drilling and in-line automated dimensional verification of more than 250 geometries of aluminum shear clips in production line, with restrictive cycle time constraints, and precision under +- 0.3 mm.
- Customer wanted a cost-effective solution for drilling the holes in the different configurations of flanges.
- From the WO, the system had to follow the hole geometry from the 3D designs for drilling the holes in the proper configuration.
- Additionally, the system also had to extract GD&T information from 3D designs with specifics properties, and to get which key characteristics were necessary to inspect.
Proposed solution
- ARITEX designed a production cell with an input, output, and discard belts, and two FANUC robots were installed, one for shear clips handling (pick & place from belts), and a shear clip drilling robot equipped with the advanced LOXIN Automatic Drilling Head (ADH).
- The cell was integrated in our customer MES system. All operations and WO management were handled from an operator HMI, a custom implementation with atxHMI.
- A stereo computer vision system was installed in the input belt and in the ADH, and both image sources were analyzed by our 3D computer vision application atxVISION. The cell inspected the input belt for flange identification and positioning, after that, the handling robot picked and placed them in the drilling jig, and the system also scanned the part for precise positioning and pre-drilling photogrammetric analysis.
- The vision system was coordinated with our metrology software atxMETRICS. Once images were analyzed, the dimensional measures were verified by atxMETRICS. If pre-drilled shear clips were defective, the cell discarded them by moving them to discard belt.
- Once positioned, the drilling robot drilled the shear clip in the WO specific geometry from its 3D designs. After drilling operation, atxVISION system performed the hole analysis.
- After hole images were analyzed, the GD&T data was verified by our atxMETRICS software. All drilled shear clips meeting the quality requirements were unloaded in the exit belt, and defective ones, in the discard belt.
- The cell met our customer cycle time and dimensional accuracy constraints. An inspection report was generated per part, and OEE and quality information was integrated into our customer QMS.
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