Construction and Performance Verification of an Automated Assembly System for Aero Engine Principal Shaft Enabled by Multi Sensor Fusion

Assembly of the low-pressure turbine rotor (LPTR) of an aero-engine requires the principal shaft to be inserted along the center of the aero-engine shaft hole precisely. The application of appropriate sensors is imperative for ensuring these aspects. In this paper, a custom automated assembly system (AAS) is developed for the LPTR assembly. First, we describe the overall structure and operation of the AAS. The sensor technology employed in the system is also described in detail, including its composition and principle of operation. Second, the kinematic model of attitude adjustment unit (AAU) is established based on the pose of the aero-engine and the LPTR. The kinematic equation of the AAS is developed based on the position closure approach which is more compact and coordinate free unlike the D-H method. Furthermore, the working principle of the integrated management control system of the working parts is introduced. Finally, the one-time assembly success rate and the assembly time are tested to verify the performance of the AAS. The results showed that the one-time assembly success rate and the assembly time both improvement compared to manual. Therefore, the application of many types of sensors is beneficial for the automation and precision assembly of the AAS.