Browse Topic: Assembling

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Elbow Assembly 45°, Flared Tube to Retained Nut, for Seal Ring** FK Test-2026-04-12 **AS4316B (Current)5/8/2026
SCOPE IS UNAVAILABLE.1
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
testing new software productSAE-SUP-TEST134/1/2026
Software Diagram https://wcm14-tst.cld.sae.org/site/binaries/content/gallery/mobilus-brx/digital-supplements/software-diagram.png/software-diagram.png/sae%3Amedium
Guidelines for Repair Process Evaluation of Fiber Reinforced Composite Bonded StructureAIR6292 (Current)11/26/2025
The SAE Aerospace Information Report (AIR) is intended to be used as a process verification guide for evaluating implementation of key factors in bonded repair of fiber reinforced composite structure in a repair shop environment. The guide will be used in conjunction with a regulatory approved and substantiated repair, and is intended to promote consistency and reliability.
AMS CACRC Commercial Aircraft Composite Repair Committee
Guidelines for Repair Process Evaluation of Aluminum Bonded StructureAIR6291A (Current)11/26/2025
This SAE Aerospace Information Report (AIR) is intended to be used as a process verification guide for evaluating implementation of key factors in repair of metal bond parts or assemblies in a repair shop environment. This guide is to be used in conjunction with a regulatory approved and substantiated repair, and is intended to promote consistency and reliability.
AMS CACRC Commercial Aircraft Composite Repair Committee
asdgjmsaldkfgjalkerjtw (Current)8/29/2024
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Airlines Electronic Engineering Committee
Automation Title for Group Code D22PC-Auto-1713447343633 (Current)4/18/2024
Automation Abstract for Group Code D22
Airlines Electronic Engineering Committee
Automation Title for Group Code D21PC-Auto-1713447321320 (Current)4/18/2024
Automation Abstract for Group Code D21
Airlines Electronic Engineering Committee
Automation Title for Group Code D21PC-CUR-1232 (Current)4/18/2024
Automation Abstract for Group Code D21
Airlines Electronic Engineering Committee
Automation Title for Group Code D23PC-Auto-1713447365379 (Current)4/18/2024
Automation Abstract for Group Code D23
Flight Simulator Engineering and Maintenance Committee
An eleventh one for CUR-1174PC11-CUR-1174 (Current)4/2/2024
Italic
Flight Simulator Engineering and Maintenance Committee
Information Report Testjms-informationreport1 (Historical)3/11/2024
Information Report Test
Aviation Maintenance Committee
Pre-print testing CSP-6572SAE-PP-091512/1/2024
Regression pre-print submission
Atash, Ganira
USUALLY UNOBSERVED REFINEMENTS OF AUTOMOBILE CONSTRUCTION0800031/1/2024
ELLSWORTH, JOHN MAGEE, FAY, THOMAS J.
PRE-print testing CSP-6572SAE-PP-0905612/12/2023
regression preprint
Atash, Ganira
Pre-print testing CSP-6572SAE-PP-0904512/8/2023
regression preprint submission
Atash, Ganira
Pre-print testing CSP-6572SAE-PP-0903112/4/2023
regression preprint submission
Atash, Ganira
Print regression testingSAE-PP-0896311/8/2023
regression preprint submission
Atash, Ganira
Preprint regression testingSAE-PP-0896211/8/2023
regression preprint submission
Atash, Ganira
test 06/19/2023auto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testSAE-PP-081656/19/2023
test 06/19/2023
Mutagaana, Festo
Attacking vehicles with ransomware: Watch the horizon2022-01-04413/29/2022
Ransomware use is rampant throughout most industries. With the number of successful ransomware attacks through the industrial economy, this feels like a tsunami of attacks. These attacks seemingly originate from anywhere with an internet connection. There are vast numbers of bad actors creating these attacks, all focused on your systems. With the large number of attacks, it is granted there have been many breaches. While there have been a large number of successful attacks, each attack’s objectives have varied. These have historically been to generate revenue in the form of fees for the decrypt key or a promise not to publish exfiltrated data. The landscape has become saturated with ransomware attacks on consumers and the enterprise. There has been extensive training for staff in an effort to mitigate these issues. The next potential targets are vehicles and ground systems. These, as targets, have not been evaluated via a full risk assessment to the recommended extent. While not widely exploited, this has the distinct potential to be a significant issue. With the criticality of these systems for the troops along with the DoD, the risk for nation-state attacks cannot be dismissed or ignored. The impact of a coordinated attack would be significant. As the vehicles increase their connectivity and level of autonomy, the risks continue to grow. The compromised ground vehicle systems may lead to the vehicles inoperable, the supply chain stopping to the soldiers in the field, and distribution systems (goods and soldiers) ceasing. The paper will analyze ransomware threats, creation, pivots from present attacks, and attack methodologies.
Parker, Charles
Requirements for Using Robotic Hot Solder Dip to Replace the Finish on Electronic Piece PartsGEIASTD0006C (Current)10/26/2021
This standard defines the requirements for fully replacing undesirable surface finishes using robotic hot solder dip. Requirements for qualifying and testing the refinished piece parts are also included. This standard covers the replacement of pure tin and Pb-free tin alloy finishes with SnPb finishes with the intent of subsequent assembly with SnPb solder. This dipping is different from dipping to within some distance of the body for the purposes of solderability; solder dipping for purposes other than full replacement of pure tin and Pb-free tin alloy finishes are beyond the scope of this document. It covers process and testing requirements for robotic dipping process and does not cover semi-automatic or purely manual dipping processes. This standard does not apply to piece-part manufacturers who build piece parts with a hot solder dip finish. It applies to refinishing performed by a robotic hot solder dip service supplier or production facilities at the customer, whenever the intent of the dipping is to have full coverage and replacement of Pb-free tin. Replacement of BGA spheres or CGA columns is not included in the scope of this standard. IEC TS 62647-4 may be used for replacement of BGA spheres. The intent of this standard is for suppliers and customers to incorporate these requirements into their operations to provide a consistent and well-controlled process for product applications that require significant control. Complete conversion of termination finishes from Pb-free tin to SnPb will allow use of piece parts for any of the Control Levels of GEIA-STD-0005-2 without mitigations. In addition to the elimination of tin whisker risks, piece parts processed to this standard will also exhibit enhanced solderability and solder joint reliability compared to most COTS finishes. Each customer shall determine the applicability of this standard and the need for full replacement of the existing termination finish. This standard does not guarantee a particular yield or reliability of piece parts going through solder dipping. Some applications may have unique requirements that exceed the scope of this standard and should be specified separately. Pb-free tin piece parts which have been dipped in compliance with this standard are no longer considered to be Pb-free tin finished for the purposes of GEIA-STD-0005-2.
G-24 Pb-free Risk Management Committee for ADHP
automobile's nviehfSAE-PP-0047610/6/2021
Current automobile's auto-transmission has problems of defects and cost reduction because of welding process and very complicated assembly process due to individualized transmission piston and sealing components. Also, size and heavy weight of transmission piston components are the source of low mileage because they are made of aluminum, steel materia
Mutagaana, Festo
Connector Accessories, Electrical General Specification forAS85049F (Current)4/14/2021
This specification covers connector accessories for use with electrical connectors; see 6.8.
AE-8C1 Connectors Committee
Numerical Simulation of Aircraft Assembly Process with Presence of Sealant2021-01-00013/2/2021
Sealant is applied between joined aircraft parts in the final stage of the assembly, before installation of permanent fasteners. In this paper a novel approach for aircraft assembly simulation is suggested, which allows to resolve the transient interaction between parts and sealant in the course of airframe assembly process. The simulation incorporates such phenomena as compliance of parts, contact interaction between them and fluidity of sealant with presence of free surface. The approach based on fluid-structure interaction techniques consists of two basic steps: at the first one the pressure of sealant is found after corresponding fluid dynamics problem is solved and at the second the displacements of parts and sealant are calculated through the solving of contact problem. Iterations between structural and fluid dynamics solvers are performed to achieve convergence. The developed approach is demonstrated on example of joining of two test aircraft panels. The viscosity of sealant was selected based on available experimental data. The results of simulations show how such parameters as fastening force and sealant layer thickness affect the assembly process.
Eliseev, Artem, Lupuleac, Sergey, Grigor'ev, Boris, Shinder, Julia, Bouriquet, Jacques
Application of Selective Assembly as an Aerospace Design for Manufacturing and Assembly Principle for Effective Variation Management in Aerospace Assemblies2021-01-00053/2/2021
Aerospace engine parts are complex precision-engineered products with tighter assembly tolerances produced by conventional and non-conventional manufacturing processes. Variations in these manufacturing processes have to be controlled, process risks mitigated, and managed effectively, to facilitate the ease of aero-engine assembly to reduce overall variation and improve the assembly quality. One such technique is the application of the Selective Assembly as a Design for Manufacturing and Assembly (DfMA) tool. The paper details the methodology of Selective Assembly, its applications, benefits, and limitations in the aerospace industry along with a framework case study with a focus on ease of assembly and meeting the design intent of the assembly fit with the detailed study on the current traditional assembly process. The focus is to analyze the current challenges faced on the application of the Selective assembly of Aero-engine components through a case study on the development and application of an Assembly Installation Operation Selective (AIOS) assembly tool, that be applied both as a built-in tool for Selective Assembly data acquisition and optimal selection. The study also investigates whether the concept of decimal roundoff in the measurement reporting process has any significant impact on the selective process capability and the pin-hole assembly fit quality. The objectives are to optimize and enhance the current assembly process to meet the customer design intent and First Time Right (FTR) quality of the assembly fit and to promote the application of the Selective Assembly concept as a potential quality and cost optimization technique in assembly processes highly subjected to variations by emphasizing its application as an Aerospace Design for Manufacturing and Assembly (ADFMA) guideline for effectively controlling and mitigating assembly variations of shafts and holes in aerospace engine parts and reducing reworks and rejections in the aerospace industry due to high process variability and need for better process control in fabrication tolerances.
Rajamani, Mani Rathinam
Thread SealantsJ1615_202101 (Current)1/27/2021
Male pipe threads, including male dryseal pipe threads, when made into assemblies or installed into ports, will generally leak if not covered with a sealant. This SAE Recommended Practice is intended as a guide to assist designers and/or users in the selection and application of various types of thread sealants. The designers and users must make a systematic review of each type and application and then select the sealant to fulfill the requirements of the application. The following are general guidelines and are not necessarily a complete list.
Air Brake Tubing and Tube Ftg Committee
The Effect of Change in Assembly Sequence on Permanent Strain of Cab Suspension Console02-13-02-00118/20/2020
Heavy commercial vehicles play an important role in creating the trade and economic balance of countries. Also, the durability and safety of heavy commercial vehicles come to the fore. Heavy commercial vehicles consist of two parts. These are the chassis area with the equipment that allows the vehicle to move and the cabin section where the driver is located. The cabin area is the most important area that ensures the highest level of driver safety. Considering that the production of trucks is increasing day by day, it is inevitable for companies to increase their R&D activities in the field of cabin and cabin suspension systems for much safer, durable, and comfortable trucks. This study aims to determine the safe torque value of the fasteners and their assembly sequence of the Cab Suspension Console, which is one of the most important connection parts in a truck and which can cause a fatal accident by breaking. In this study, the safe torque value of the fasteners of the cabin suspension console has been determined as 180 ± 15 Nm/180 ± 10 Grad for the outer fasteners and 225 ± 18 Nm/180 ± 10 Grad for the inner fasteners. In addition, two different assembly sequences are determined and permanent strains on the part are measured. At the end of the assembly test, permanent strains on the part and other factors affecting the strain are simulated. According to the results obtained, the assembly sequence with a low permanent strain value is chosen and commissioned in production.
Yildirim, Bariscan, Öztürk, Dogan
LSR Technology: A New Dimension in Design of Medical DevicesTBMG-373498/1/2020
Today’s medical device manufacturers are facing changing and more challenging requirements for their products. Users are demanding less-invasive devices, and in some cases, wearable devices that are robust and long lasting. Regulations are becoming ever more stringent and costly, especially in terms of biodegradability. Yet at the same time, device manufacturers want to meet user demands by including the latest technologies, while keeping their costs under control.
A Communication-Free Human-Robot-Collaboration Approach for Aircraft Riveting Process Using AI Probabilistic Planning2020-01-00133/10/2020
In large scale industries attempts are continuously being made to automate assembly processes to not only increase productivity but also alleviate non-ergonomic tasks. However this is not always technologically possible due to specific joining challenges and the high number of special-purpose parts. For the riveting process, for example, semi-automated approaches represent an alternative to optimizing aircraft assembly and to reduce the exposure of workers to non-ergonomic conditions entailed by performing repetitive tasks. In [1], a semi-automated solution is proposed for the riveting process of assembling the section barrel of the aft section to its pressure bulkhead. The method introduced a dynamic task sharing strategy between human and robot that implements interaction possibilities to establish a communication between a human and a robot in Human-Robot-collaboration fashion. Although intuitive, interacting with the robot constantly is still not natural for the worker as in the manual process no explicit communication between both workers is needed. In this work a communication-free Human-Robot-collaboration solution is presented. The method developed not only enables sharing assembly missions by dividing tasks based on skills, but also offers the possibility of decision making to the robot. In this context, off-the-shelf Artificial Intelligence planning tools are used to model the work-flow of the human as well as the task of the robot handling alongside possible uncertainties yielding while perceiving the environment or the activity of the human.
Rekik, Khansa, Müller, Rainer, Hoffmann, Jörg, Vette, Matthias
Case Study on the Challenges and Responses of a Large Turnkey Assembly Line for the C919 Wing2020-01-00103/10/2020
Design and production of an assembly system for a major aircraft component is a complex undertaking, which demands a large-scale system view. Electroimpact has completed a turnkey assembly line for producing the wing, flap, and aileron structures for the COMAC C919 aircraft in Xi’an, China. The project scope includes assembly process design, material handling design, equipment design, manufacture, installation, and first article production support. Inputs to the assembly line are individual component parts and small subassemblies. The assembly line output is a structurally completed set of wing box, flaps, and ailerons, for delivery to the Final Assembly Line in Shanghai. There is a trend toward defining an assembly line procurement contract by production capacity, versus a list of components, which implies that an equipment supplier must become an owner of production processes. The most significant challenge faced was the amount of front end engineering work required to develop detailed assembly processes and reconcile them with the customer, who remains the actual process owner. Other challenges include aircraft maturity delays, design changes due to process definition evolution, factory environmental conditions such as dust and varying temperature gradients, and cultural and communication challenges both internal and external. The result achieved by Electroimpact is an assembly line system composed of an integration of assembly tooling, special process equipment, NC machine equipment, inspection equipment, material handling and logistics equipment: Two robotic drilling cells integrated with both stationary and mobile tooling. Integrated wing major assembly cell with manual assembly jigs and large CNC wing drilling machines. Twenty-three other manual work stations. New technology developments implemented include: A new high-curvature nosepiece on the robot end effecter to enable accurate drilling and countersinking on the LE Spar D-Nose section. A new application and delivery system for single-sided temporary fasteners for wing panel drilling. Tooling design to accommodate large temperature variations.
Forbes, Mark
A Study on the Development of Aerostructures Design for Assembly Guidelines and Their Effective Use to Proactively Identify Opportunities for Improvement in Mitigating Common Defects of the Aerostructures Assembly2020-01-00093/10/2020
An Aircraft’s assembly process plays a vital part in its design, development and production phases and contributes to about half of the Total cost spent in its entire product lifecycle. Design For Assembly (DFA®) principles have been one of the proven effective methodologies in Automotive and Process industries. Use of DFA® principles have resulted in proactively simplifying and optimizing engineering designs with reduced product costs, and improved efficiencies in product design and performance. Standardization of Assembly guidelines is vital for “Design and Build” and “Build-To-Print” manufacturing supplier organizations. However, Standardizing design methodologies, through use of proven tools like Advanced Product Quality Planning, (APQP) are still in the initial stages in Aerospace part and process design processes. Thus, there is a tremendous opportunity for research on the application of the existing DFA® guidelines to optimize Engineering Aerospace Assembly processes aiming to simplify, standardize design methodologies by building on existing industry practices which have a common platform for design communication and are easy to adopt within the existing process/systems. This technical paper is to discuss the framework for application of DFA® principles and design guidelines specifically aimed for engineering optimization of Aerospace Assembly Process Designs. The Aerospace DFA® implementation framework proposed in this paper is based on the study on the application of the existing DFA® guidelines proven and used in other Process industries to Aerospace Part and Process Design and development. This paper collates the findings, experiences and learnings gained during the study collated from a research point of view using Six Sigma methodology DMAIC and DMADV. This paper also focuses on the use and publication of this research outputs on Aerospace industry applicable DFA® guidelines, which can be used as a reference for emerging Aerospace designers in their future and current designs.
Rajamani, Mani Rathinam, Punna, Eshwaraiah
Celebrating Women in Engineering & Science: Mary Hardgrove, Assembly SupervisorTBMG-361863/1/2020
Dynamic Gripper Mimics Adjustable Grip of the Human HandTBMG-359952/1/2020
Human hands can alter the firmness of their grip. A new two-fingered robotic hand shares that trait. The design enables it to absorb energy from impacts during collisions, preventing whatever the robot is holding from breaking and making it safer for people to work with and near the machines.
Making Connections to Accelerate Medical Device AssemblyTBMG-360262/1/2020
As medical devices become smaller and more complex, designers and manufacturers are utilizing new and more sophisticated components to incorporate into their device designs. Patients want smaller, more portable devices while providers want more functional and better performing alternatives. This includes items such as IV tubes and bags, drainage catheters, dialysis machine tubing, and a host of other products using tubing and hoses.
Mitigating Wire Insulation Damage During Processing and HandlingAIR5717 (Current)12/27/2019
Wire and cable products progress through a series of handling or operational steps from the time they leave the manufacturer, and until a finished harness or assembly is ready for installation on a vehicle. Throughout these many steps, environmental or processing conditions may be present which can generate damage detrimental to the wire or cable and/or its intended application.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Influence of cutting fluid on reliability of threaded fastener joints2019-01-230012/19/2019
This study reports on the effect of cutting fluids on friction behavior of the threaded fasteners. Underhead and thread friction are measured during tightening process of the hex-head threaded fasteners coated with different zinc-based coatings: electroplated zinc, zinc flake, and electroplated zinc nickel, commonly used in the automotive industry. The tests and data analysis are conducted considering ISO 16047 as a baseline. Test conditions are set close to the actual production conditions found in the motor vehicle industry. Water-based and ester-based cutting fluids are selected to unveil their impact on the reliability of the threaded fastener joints. It is shown that a change in the underhead interface conditions from dry to lubricated drastically reduces friction for the electroplated zinc and zinc nickel coatings.
Kumar, Mayank, Persson, Erik, Glavatskih, Sergei
The Role of Sensors in the Evolution of RoboticsTBMG-3560912/1/2019
At one time, robotics was considered more science fiction than reality. That's changing. Today, robots are increasingly playing a role in our everyday lives. They're zooming around our homes to pick up dust, helping surgeons perform operations with even more precision, sniffing out suspicious packages for law enforcement, and on the factory floor, they're performing all kinds of tasks for automotive, electronics, and industrial manufacturing companies.
Enhanced Radio Frequency Identification (RFID) ReaderTBMG-3569112/1/2019
NASA's Johnson Space Center has developed a suite of RFID-based technologies focused on improving communication of an RFID reader with a greater number of RFID tags in open and enclosed areas.
How Augmented Reality Can Modernize Aerospace And Defense ManufacturingTBMG-3568512/1/2019
You've probably heard about augmented reality (AR) in the context of consumer entertainment: video gaming, virtual tours, or interactive displays. But AR for enterprise business is here. It's no longer an emerging technology, or a novelty; businesses are using AR to overhaul processes, drive efficiencies, reduce manufacturing errors, and improve their bottom line.
Robots Can Pick Up Any Object After Inspecting ItTBMG-3542511/1/2019
For decades, robots in controlled environments like assembly lines have been able to pick up the same object over and over again. More recently, breakthroughs in computer vision have enabled robots to make basic distinctions between objects. Even then, though, the systems don’t truly understand objects’ shapes, so there’s little the robots can do after a quick pickup.
Reducing Risk with Geometric Transition ExtrusionTBMG-3549811/1/2019
In an effort to design smaller, more intricate and complicated medical devices without running afoul of increasingly stringent national and international regulations, many designers are looking to geometric transition extrusions manufactured of high consistency rubber (HCR) silicone. This process reduces total cost of ownership for the original equipment manufacturer while improving part quality and greatly enhancing the types of devices being sought by healthcare providers.
Mathematical Technique Quickly Tunes Next-Generation LensesTBMG-3548011/1/2019
Most of us know optical lenses as curved, transparent pieces of plastic or glass, designed to focus light for microscopes, spectacles, cameras, and more. For the most part, a lens’ curved shape has not changed much since it was invented many centuries ago.
A Strip You Can Rely On: Tips for Designing Blood Glucose Test StripsTBMG-3533510/1/2019
When it comes to diabetes management, accurate blood glucose readings are paramount. And when it comes to generating accurate readings, the quality of the test strip is dependent upon the materials used in its design — each layer has to be able to perform its function without interference from other layers or external contamination.
Deep-Space Food Science Research Improves 3D PrintingTBMG-3528210/1/2019
Spinoff is NASA’s annual publication featuring successfully commercialized NASA technology. This commercialization has contributed to the development of products and services in the fields of health and medicine, consumer goods, transportation, public safety, computer technology, and environmental resources.
Advanced Assembly Solutions for the Airbus RACER Joined-Wing Configuration2019-01-18849/16/2019
The Rapid And Cost Effective Rotorcraft (RACER) is being developed by Airbus Helicopters (AH) to demonstrate a new Vertical Take-Off and Landing configuration to fill the mobility gap between conventional helicopters and aeroplanes. RACER is a compound rotorcraft featuring wings and multiple rotors. The wing arrangement suggested by AH is defined as a staggered bi-plane joined configuration with an upper and a lower straight wing, either side of the fuselage, connected at their outboard extent to form a triangular structure. The ASTRAL consortium, consisting of the University of Nottingham and GE Aviation Systems, are responsible for the design, manufacture, assembly and testing of the wings. Producing an optimised strategy to assemble a joined-wing configuration for a passenger carrying rotorcraft is challenging and novel. The objective of this work concerns all aspects of assembling the joined-wing structure. The joined-wing and fuselage structures will be produced independently and mated together during the final RACER assembly. A multi-stage process will deliver the joined-wing assembly and ensure it will fit to the fuselage. Producing the individual wing structures requires a novel build philosophy driven by the innovative, one-piece composite moulding that forms the leading edge (LE) and upper aerodynamic surface of each wing. Using the Flap sub-assembly as the tool to set interfacing wing-box items provides a cost effective solution to assembly jig design. The independent wing structures must be joined at the outboard hinge line, whilst meeting the fuselage interchangeability definition. Matched tooling, replicating the fuselage interface, will be employed to overcome this hurdle. Successfully joining the wing structures also requires the innovative application of 3D tolerance analysis methods to size bush diameters within the interface. The overall build philosophy is summarised in this work, including assembly sequencing; definition of datum frames; assembly tooling; design tolerances and the analysis required to deliver assembly key characteristics.
Bainbridge, David, Bacharoudis, Konstantinos, Cini, Andrea, Turner, Alison, Popov, Atanas, Ratchev, Svetan
C919 Trailing Edge Assembly Interchangeable Tooling2019-01-18809/16/2019
Traditional Trailing Edge (TE) assembly that utilise fixtures for accurate positioning of aircraft (a/c) parts do not allow for removal of specific tooling from the fixtures to travel with the TE, post assembly. Instead, the tooling that positions all the primary a/c assembly datums generally utilise precision pins of various sizes that index and clamp the a/c ribs. Often it is difficult to remove the pins post assembly before the spar can be taken out of the fixture. Use of hammers is common place to hit pins out of holes which is less than ideal considering the a/c parts can be fragile and the tooling is precision set. Also, the Main Assembly Fixture (MAJ) that will receive the TE will inevitably need to relocate some if not all the primary a/c ribs and therefore will most likely be subject to some amount of persuasion. Electroimpact have for many years used cup cone locators that allows static tooling to be temporarily ‘loosened’ and therefore made more compliant for pin insertion/removal, this has been successful to reduce the need for hammering, but doesn’t remove the necessity for extensive manual work to reclaim all the datums. The intent of this paper is to highlight how we, on the C919 project, have successfully designed and implemented the use of removable tooling that travels with the TE sub-assemblies into the main TE assembly fixture and similarly the same interchangeable and removable tooling travels with the completed TE and re-engages with identical tooling receivers in the MAJ. Providing a fast, efficient, reduced man-power and accurate means for building a TE and transfer into the MAJ.
Dineley, James
Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly2019-01-18779/16/2019
Reconfigurable tooling frames consisting of steel box sections and bolted friction clamps offer an opportunity to replace traditional expensive welded steel tooling. This well publicized reconfigurable reusable jig tooling has been investigated for use in the assembly of a prototype compound helicopter wing. Due to the aircraft configuration, the wing design is pinned at both ends and therefore requires a higher degree of end to end accuracy, over the 4m length, than conventional wings. During the investigation some fundamental issues are approached, including: Potential cost savings and variables which effect the business case. Achievable Jig accuracy. Potential sources of instability that may affect accuracy over time. Repeatability of measurements with various features and methods. Typical jig stability over 24hrs including effects of small temperature fluctuations. Deflections that occur due to loading. The cost benefit of reusable tooling in a low volume prototype scenario is examined followed by the design of the jig and location features to enable the accurate build and certification documentation to be completed. A prototype 4m test jig comprising of commercially available components and bespoke machined ‘pick-ups’ is presented. Hardware and measurement process cost modelling is documented along with results for the positional and center-line concentricity setting accuracy that was achieved using a Leica AT901 laser tracking system. Subsequent measurements over a 24hr period are also discussed along with potential sources of deviation in jig accuracy over time and with an applied load.
Crossley, Richard J., Ratchev, Svetan
A New Positioning Device Designed for Aircraft Automated Alignment System2019-01-18839/16/2019
Accurate and fast positioning of large aircraft component is of great importance for Automated Alignment System. The Ball joint is a widely-used mechanical device connecting the aircraft component and positioners. However, there are some shortcomings for the device in man-machine engineering, such as the entry state of the ball-head still needs to be confirmed by the workers and then switched to the locking state manually. To solve above problems, a new positioning mechanism is present in this paper, which consists of a ball-head and a ball-socket. The new device is equipped with a monocular vision system, in which a calibrated industrial camera is used to collect the images of the ball-head. And then, the 3-D coordinate of the ball-head center is calculated by a designed algorithm, guiding the positioner to capture the ball-head. Once the ball-head gets into the ball-socket, the pneumatic system will drive the pistons to move to the specified location. Meanwhile, the amount of compression of a set of springs has changed, so the steel balls are compelled to compress, contact or separate the ball-head, which means the states can be switched automatically. At last, an experiment is carried out to verify the accuracy of the visual system by comparing the measurement results with the laser tracker. The experimental results indicate that the design of the new positioning device with ergonomics can not only reduce the labor intensity, but also improve the assembly efficiency.
Huang, Jie, Yu, Long, Zhang, Yilian, Wang, Yuhan
Simulation of Aircraft Assembly via ASRP Software2019-01-18879/16/2019
ASRP (Assembly Simulation of Riveting Process) software is a special tool for assembly process modelling for large scale airframe parts. On the base of variation simulation, ASRP provides a convenient way to analyze, verify and optimize the arrangement of temporary fasteners. During the assembly of airframe certain criteria on residual gap between parts must be fulfilled. The numerical approach implemented in ASRP allows to evaluate the quality of contact on every stage of assembly process and solve verification and optimization problems for temporary fastener patterns. The paper is devoted to description of several specialized approaches that combine statistical analysis of measured data and numerical simulation using high-performance computing for optimization of fastener patterns, calculation of forces in fasteners needed to close initial gaps, and identification of hazardous areas in junction regions via ASRP software.
Zaitseva, Nadezhda, Pogarskaia, Tatiana, Minevich, Olga, Shinder, Julia, Bonhomme, Elodie
Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint2019-01-18829/16/2019
The paper presents the numerical approach to simulation and optimization of A350 S19 splice assembly process. The main goal is to reduce the number of installed temporary fasteners while preventing the gap between parts from opening during drilling stage. The numerical approach includes computation of residual gaps between parts, optimization of fastener pattern and validation of obtained solution on input data generated on the base of available measurements. The problem is solved with ASRP (Assembly Simulation of Riveting Process) software. The described methodology is applied to the optimization of the robotized assembly process for A350 S19 section.
Lupuleac, Sergey, Shinder, Julia, Churilova, Maria, Zaitseva, Nadezhda, Khashba, Valeriia, Bonhomme, Elodie, Montero-Sanjuan, Pedro
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