A Study on Improving Efficiency and Reliability of Automated Connector Testing for Aerospace Applications

Abstract

Automation is crucial for the future of the industry as it enhances efficiency, quality, and accuracy while reducing operating time and the occurrence of human errors. Establishing an automated factory requires significant resources, including robot installation, worker training, program development, and ensuring quality and safety measures. This paper presents a study on automating the testing process for an aerospace company aiming to enhance productivity and minimise errors. The study aimed to achieve full task automation using a Universal Robotics Arm (UR5), which undertook the tasks of retrieving, inserting, securely locking, and removing the six connectors into the equipment, effectively executing the entire process. In initial trials, wireless connectors exceeded expectations, achieving 16 cycles in 2 hours. The inclusion of cables brought about significant challenges, particularly in terms of cable entanglement and concerns regarding the durability of connectors. Proposed solutions include improving the rack system and refining the gripper’s functionalities. This highlights the project’s potential for transformative advancements in aerospace manufacturing.