Drilling task planning and offline programming of a robotic multi-spindle drilling system for aero-engine nacelle acoustic liners

Abstract

Aero-engine nacelle acoustic liners are complex curved surface subassemblies with tens of thousands of dense acoustic holes for noise reduction. Traditional robotic drilling systems with a single spindle and conventional teaching programming cannot meet the high-quality and high-efficiency drilling requirements for nacelle acoustic liners. This paper developed a novel robotic multi-spindle drilling system, which integrates standard industrial robots with a multi-spindle drilling end-effector to drill acoustic holes on an acoustic liner. The task planning strategy and offline programming method are investigated for the robotic multi-spindle drilling of the acoustic liner. A dedicated offline programming software capable of quickly generating robotic machining programs has been designed and developed. A precise acoustic hole arrangement applicable to curved drilling zones is demonstrated. The virtual surrogate hole is introduced to target the array layout of the developed end-effector's multiple spindles. A virtual surrogate hole generation method is proposed based on the minimum mutually exclusive set cover and the greedy algorithm. After that, a virtual surrogate hole layout optimization method is developed using an adaptive genetic annealing algorithm. Then, the frame chain is constructed as the kinematic foundation in robotic multi-spindle drilling of a nacelle acoustic liner. The drilling pose planning of the multi-spindle end-effector based on normal vectors and coordinates of acoustic hole points covered by virtual surrogate holes is explored. And a multi-spindle drilling path planning algorithm is developed using the genetic algorithm. To drill the aero-engine nacelle of a large aircraft, an offline programming software for robotic multi-spindle drilling of the nacelle acoustic liner is developed by integrating the methods above. A case study of multi-spindle drilling task planning of a nacelle acoustic liner is carried out. The case study results indicate that, compared to traditional single-spindle robotic drilling systems, the developed multi-spindle drilling system increases drilling efficiency by approximately 347 %. Using the proposed multi-spindle drilling path optimization algorithm, the drilling path has been shortened by 84.8 %. These results validate the effectiveness of the proposed series of drilling task planning methods and the developed offline programming software, which significantly enhance drilling efficiency while meeting the technical requirements for drilling acoustic holes on the acoustic liner.