Design and analysis of an end-of-arm robotic drilling tool for aerospace manufacturing with active vibration control

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dc.contributor.authorKazemiesfahani, Mahdi
dc.contributor.examiningcommitteeFerguson, Philip (Mechanical Engineering)
dc.contributor.examiningcommitteeWang, Jay (Mechanical Engineering)
dc.contributor.supervisorKhoshdarregi, Matt
dc.date.accessioned2025-04-28T20:42:53Z
dc.date.available2025-04-28T20:42:53Z
dc.date.issued2025-04-23
dc.date.submitted2025-04-23T22:19:04Zen_US
dc.degree.disciplineMechanical Engineering
dc.degree.levelMaster of Science (M.Sc.)
dc.description.abstractAutomated drilling is crucial in aerospace manufacturing, significantly impacting production efficiency, quality, and safety. This thesis presents the design, prototyping, and analysis of the Advanced Collaborative Multifunctional End-Effector (ACME), a robotic drilling tool specifically developed for aerospace applications. ACME addresses key industry challenges by integrating lightweight design, collaborative robot (cobot) compatibility, precise positional control, and advanced vibration suppression capabilities. ACME utilizes mechanisms for efficient planar movement, combined with a passive self-normalizing drilling head capable of maintaining normality on complex, double-curvature surfaces. The device is engineered to provide high clamping forces essential for multi-layered material stacks, while remaining within the payload limits of commercially available cobots. Experimental verification confirmed ACME’s operational efficacy, achieving target performance metrics including a maximum clamping force exceeding 1000 N, rapid drilling cycles of approximately 12 seconds per hole, and an optimal workspace suitable for typical aerospace panel configurations. Despite minor deviations in geometric hole quality compared to CNC benchmarks, results were within acceptable aerospace standards. A comprehensive dynamic model, developed and verified experimentally through frequency response functions (FRF), effectively characterizes system behaviors and supports precise vibration control. The thesis further investigates active vibration control (AVC) methods employing voice coil actuators (VCAs), demonstrating significant reductions in operational vibration amplitudes and enhancing overall drilling precision. The outcomes highlight ACME’s potential as a cost-effective, flexible, and high-precision automated drilling solution for aerospace manufacturing, laying the groundwork for future advancements in robotic automation and vibration control strategies.
dc.description.noteOctober 2025
dc.identifier.urihttp://hdl.handle.net/1993/39050
dc.language.isoeng
dc.subjectRobotic Drilling
dc.subjectAerospace Manufacturing
dc.subjectEnd-of-Arm Tooling
dc.subjectCollaborative Robots (Cobots)
dc.subjectActive Vibration Control (AVC)
dc.subjectDynamic Modelling
dc.subjectVoice Coil Actuator (VCA)
dc.subjectDesign
dc.subjectPrototyping
dc.titleDesign and analysis of an end-of-arm robotic drilling tool for aerospace manufacturing with active vibration control
local.subject.manitobano
project.funder.identifierhttp://dx.doi.org/10.13039/501100000046
project.funder.nameNational Research Council Canada
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