_Variability_ _is traditionally the enemy of automation__, but with today's focus on customisation and choice this needs to change. To be widely used and adopted across UK manufacturing. automation must be able to handle large dimensional changes and be capable of changing quickly and effectively between different operations. This project addresses this issue with the development and application of an adaptive path planning system that will alter the pre-set robot program whilst in use so that changes in part shape and size can be accommodated._ _A technology demonstrator of an automated linishing and polishing_ _automation cell will be built_ _to highly polish plastic parts. The system will have the capability to measure and react to the size, shape and requirements of the part to be processed thereby making it self-programming and adapting._ _Blanson_ _are a manufacturer of highly engineered acrylic parts and will be supported by two SME, robotic technology partners, A3L and HAL Robotics. A3L are robotic integrators focused on delivering automated finishing operations to SME's but they hope to become a high-end global supplier of automated finishing solutions. HAL Robotics are specialists in adaptive robot path planning, their software Framework allows the use of sensor or/and measurement data to alter robot programs 'on the fly' thereby allowing for the process to be flexible and controlled by the attributes of the part._ A3L will work together with HAL to deliver an innovative finishing solution that can be utilised within Blanson's manufacturing facility. We are aiming for a 'one size fits all' approach to finishing automation, i.e., the system will be able to process multiple parts without reprogramming. It will utilise sensor data to determine where the process needs to be applied and when it is complete i.e., surface roughness or part geometry readings will be fed back into a software solution which will determine fitness and automatically generate any necessary corrective robot toolpaths. AI will also be used to process data to optimise use of abrasive consumables. Current best practice is to use the abrasives for a set time period and then dispose of them (whether they are spent or not), we believe the volume of consumables used monthly can be greatly reduced delivering huge cost savings and driving a greener approach.

Responding to a challenge form the UK Aerospace Technology Institute, a consortium of six innovative small businesses – known as AMROCCS – are collaborating to convert a bright idea into reality and keep the UK as world no.2 in aviation. MRO means “maintenance, repair and overhaul” of aircraft – high quality MRO is vital to keep aircraft flying safely. Modern aircraft are designed by computer, but the question the AMROCCS group asked was how the digital world could be applied to MRO so it was even safer and more efficient, and trigger an engineering step-change. Their answer is to integrate many visual scanning technologies to capture changes in individual aircraft in an “as-is” digital model. An MRO technician wearing a wifi headset could “see” the repair needed, diagnose the fault, consult on-line expert engineers, receive training and structured work instructions, take delivery of exactly the parts and tools needed and, when finished, know the record had updated automatically. Supported by strategic partners Siemens, EasyJet, Marshall Aerospace and Autodesk, AMROCCS is based at the AMRC HVM Catapult in Sheffield for the 30 month R&D project.

A key limiting factor to the UK’s current strategy of expanding its high value manufacturing sector is the supply of ably skilled workers. Highly skilled engineers and technicians are becoming harder to find and this will be exacerbated in the future by the high number retiring over the next ten years (baby boom of the late 1940-50’s). Advanced Aerospace Assembly Ltd. (A3) has realised through innovative research that the integration of two technologies with the addition of intelligent tools and sensors will create a new product that enables engineering staff to carry out complex part assembly operations with a reduced number of errors. Optical and laser projection systems both display manufacturing information directly onto the part. The optical system can show a great deal of information across a vast area, with different colours and the laser system can highlight edges on the part very accurately. The new product will directly guide an unskilled worker through a complex manufacturing task, utilising digital sensors to ensure that the probability of a mistake is at a minimum. The technician will be able to work in an environment where the necessary manufacturing information is clearly projected directly onto the part or workstation. Critical process measurement data such as torque values and flushness etc will be automatically recorded and logged by the integration of intelligent tools into the system. This would assist manufacturing companies in reducing errors and enable new workers to quickly gain the required skills. The key objective of this proof of market is to assess the commercial viability of the Intelligent Work System (IWS), to establish the full extent of the UK, EU and global markets and to gain a thorough understanding of the real needs and requirements of key stakeholders, potential partners and customers. The early mapping of the market opportunities will significantly accelerate the development and realisation of the product.